Sinumerik 840D SL - 828D - Extended Functions

Extended Functions ___________________
Preface
A4: Digital and analog NCK
___________________
I/Os for SINUMERIK 840D sl 1
___________________
B3: Distributed systems
- 840D sl only 2
___________________
H1: Manual and handwheel
travel 3
SINUMERIK
___________________
K3: Compensations 4
SINUMERIK 840D sl / 828D ___________________
K5: Mode groups, channels,
axis interchange 5
Extended Functions
___________________
M1: Kinematic
transformation 6
___________________
M5: Measurement 7
Function Manual
___________
N3: Software cams, position
8
switching cycles
- only 840D sl
___________________
N4: Own channel
- only 840D sl 9
___________________
P2: Positioning axes 10
___________________
P5: Oscillation - only 840D sl 11
___________________
R2: Rotary axes 12
___________________
S3: Synchronous spindle 13
___________________
S7: Memory configuration 14
___________________
T1: Indexing axes 15
___________________
W3: Tool change 16
___________________
W4: Grinding-specific tool
offset and tool monitoring 17
Valid for
___________________
Z2: NC/PLC interface signals 18
Controls
SINUMERIK 840D sl / 840DE sl ___________________
Appendix A
SINUMERIK 828D
Software version
CNC software 4.5 SP2
03/2013
6FC5397-1BP40-3BA1
Legal information
Warning notice system
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damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG Order number: 6FC5397-1BP40-3BA1 Copyright Siemens AG 1994 - 2013.

Industry Sector 05/2013 Technical data subject to change All rights reserved
Postfach 48 48
90026 NRNBERG
GERMANY
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
General documentation
User documentation
Manufacturer/service documentation
Additional information
You can find information on the following topics at www.siemens.com/motioncontrol/docu:
Ordering documentation/overview of documentation
Additional links to download documents
Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
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My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content:
www.siemens.com/mdm
Training
For information about the range of training courses, refer under:
www.siemens.com/sitrain
SITRAIN - Siemens training for products, systems and solutions in automation technology
www.siemens.com/sinutrain
SinuTrain - training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support. http://support.automation.siemens.com
Extended Functions
Function Manual, 03/2013, 6FC5397-1BP40-3BA1 3
Preface
SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
Target group
This publication is intended for:
Project engineers
Technologists (from machine manufacturers)
System startup engineers (Systems/Machines)
Programmers
Benefits
The function manual describes the functions so that the target group knows them and can
select them. It provides the target group with the information required to implement the
functions.
Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.
Technical Support
You will find telephone numbers for other countries for technical support in the Internet under
http://www.siemens.com/automation/service&support
Extended Functions
4 Function Manual, 03/2013, 6FC5397-1BP40-3BA1
Preface
Information on structure and contents
Installation
Structure of this Function Manual:
Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well
as the software and the version for which this version of the Function Manual is
applicable and the overview of the individual functional descriptions.
Description of the functions in alphabetical order (e.g. A2, A3, B1, etc.)
Appendix with:
List of abbreviations
Documentation overview
Index of terms
Note
For detailed descriptions of data and alarms see:
For machine and setting data:
Detailed description of machine data (only electronically on DOConCD or DOConWEB)
For NC/PLC interface signals:
Function Manual, Basic Functions; NC/PLC Interface Signals (Z1)
Function Manual, Basic Functions; NC/PLC Interface Signals (Z2)
Function Manual, Special Functions; NC/PLC Interface Signals (Z3)
For alarms:
Diagnostics Manual
Notation of system data

The following notation is applicable for system data in this documentation:
Signal/Data Notation Example

NC/PLC interface ... NC/PLC interface signal: When the new gear stage is engaged, the following NC/PLC
signals <signal address> (<signal name>) interface signals are set by the PLC program:
DB31, ... DBX16.0-2 (actual gear stage A to C)
DB31, ... DBX16.3 (gear is changed)
Machine data ... machine data: Master spindle is the spindle stored in the machine data:
<Type><Number> <Complete MD20090 $MC_SPIND_DEF_MASTER_SPIND (position of
Designator> (<Meaning>) deletion of the master spindle in the channel)
Setting data ... setting data: The logical master spindle is contained in the setting data:
<Type><Number> <Complete SD42800 $SC_SPIND_ASSIGN_TAB[0] (spindle number
Designator> (<Meaning>) converter)
Extended Functions
Preface
Note
Signal address
The description of functions include as <signal address> of an NC/PLC interface signal, only
the address valid for SINUMERIK 840D sl. The signal address for SINUMERIK 828D should
be taken from the data lists "Signals to/from ..." at the end of the particular description of
functions.
Quantity structure
Explanations concerning the NC/PLC interface are based on the absolute maximum number
of sequential components:
Mode groups (DB11)
Channels (DB21, etc.)
Axes/spindles (DB31, etc.)
Data types
The control provides the following data types that can be used for programming in part
programs:
Type Meaning Range of values

INT Signed integers -2.147.483.648 ... +2.147.483.647
REAL Numbers with decimal point 5,0*10-324 1,7*10+308
BOOL Boolean values TRUE (0) , FALSE (0)
CHAR ASCII characters and bytes 0 ... 255 or -128 ... 127
STRING Character string, null-terminated Maximum of 400 characters + /0
(no special characters)
AXIS Axis names All axis names available in the control
system
FRAME Geometrical parameters for moving, rotating, scaling, and ---
mirroring
Note
Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible.
Extended Functions
Contents
Preface ...................................................................................................................................................... 3
1 A4: Digital and analog NCK I/Os for SINUMERIK 840D sl....................................................................... 25
1.1 Introduction ..................................................................................................................................25
1.2 Access via PLC ............................................................................................................................27
1.2.1 Brief description ...........................................................................................................................27
1.2.2 Configuration of the NCK I/Os .....................................................................................................28
1.2.3 NCK digital inputs/outputs............................................................................................................31
1.2.3.1 NCK digital inputs ........................................................................................................................31
1.2.3.2 NCK digital outputs ......................................................................................................................32
1.2.3.3 Connection and logic operations of fast digital NCK I/Os............................................................35
1.2.4 NCK analog I/Os ..........................................................................................................................37
1.2.4.1 NCK analog inputs .......................................................................................................................37
1.2.4.2 NCK analog outputs.....................................................................................................................39
1.2.4.3 Representation of the NCK analog input/output values...............................................................43
1.2.5 Comparator inputs .......................................................................................................................45
1.2.6 Direct PLC I/Os, addressable from the NC..................................................................................48
1.2.6.1 Function .......................................................................................................................................48
1.2.6.2 Supplementary conditions............................................................................................................51
1.2.6.3 Examples .....................................................................................................................................52
1.3 Access via PROFIBUS ................................................................................................................54
1.3.1 Brief description ...........................................................................................................................54
1.3.2 Configuration of the I/O ranges....................................................................................................56
1.3.3 Data exchange .............................................................................................................................58
1.3.3.1 Communication via part programs/synchronous actions.............................................................58
1.3.3.2 Communication via compile cycles ..............................................................................................61
1.3.4 Supplementary conditions............................................................................................................62
1.3.5 Examples .....................................................................................................................................63
1.3.5.1 PROFIBUS-I/O in write direction..................................................................................................63
1.3.5.2 PROFIBUS-I/O in read direction ..................................................................................................65
1.3.5.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write direction" .....................................66
1.4 Data lists ......................................................................................................................................68
1.4.1 Machine data................................................................................................................................68
1.4.1.1 General machine data..................................................................................................................68
1.4.1.2 Channelspecific machine data .....................................................................................................69
1.4.2 Setting data ..................................................................................................................................69
1.4.2.1 General setting data.....................................................................................................................69
1.4.3 Signals .........................................................................................................................................69
1.4.3.1 Signals to NC ...............................................................................................................................69
1.4.3.2 Signals from NC...........................................................................................................................70
Extended Functions
Contents
2 B3: Distributed systems - 840D sl only .................................................................................................... 71

2.1 Brief description .......................................................................................................................... 71
2.1.1 Several operator panels on several NCUs (T:M:N) .................................................................... 71
2.1.2 NCU link ...................................................................................................................................... 74
2.1.2.1 Link communication .................................................................................................................... 74
2.1.2.2 Link variables .............................................................................................................................. 75
2.1.2.3 Link axes ..................................................................................................................................... 75
2.1.2.4 Lead link axes ............................................................................................................................. 76
2.1.2.5 Dependencies ............................................................................................................................. 76
2.1.2.6 Application example: Rotary indexing machine .......................................................................... 77
2.2 NCU link ...................................................................................................................................... 79
2.2.1 Link communication .................................................................................................................... 79
2.2.1.1 General information..................................................................................................................... 79
2.2.1.2 Link module................................................................................................................................. 83
2.2.1.3 Parameter assignment: NC system cycles ................................................................................. 83
2.2.1.4 Parameter assignment: Link communication .............................................................................. 85
2.2.1.5 Configuration............................................................................................................................... 85
2.2.1.6 Wiring the NCUs ......................................................................................................................... 86
2.2.1.7 Activation..................................................................................................................................... 86
2.2.2 Link variables .............................................................................................................................. 87
2.2.2.1 Properties of the link variables memory...................................................................................... 88
2.2.2.2 Properties of the link variables.................................................................................................... 88
2.2.2.3 Write elements ............................................................................................................................ 89
2.2.2.4 Dynamic response during write................................................................................................... 90
2.2.2.5 System variable........................................................................................................................... 90
2.2.2.6 Synchronization of a write request.............................................................................................. 91
2.2.2.7 Example: Structure of the link variables memory ....................................................................... 91
2.2.2.8 Example: Read drive data........................................................................................................... 93
2.2.3 Link axes ..................................................................................................................................... 94
2.2.3.1 General information..................................................................................................................... 94
2.2.3.2 Name of a link axis...................................................................................................................... 96
2.2.3.3 Parameterization ......................................................................................................................... 96
2.2.3.4 Auxiliary function output for spindles .......................................................................................... 97
2.2.3.5 Supplementary conditions........................................................................................................... 98
2.2.4 Axis container............................................................................................................................ 100
2.2.4.1 General information................................................................................................................... 100
2.2.4.2 Parameterization ....................................................................................................................... 103
2.2.4.3 Programming............................................................................................................................. 110
2.2.4.4 System variable......................................................................................................................... 111
2.2.4.5 Machining with axis container (schematic) ............................................................................... 112
2.2.4.6 Behavior in different operating states ....................................................................................... 113
2.2.4.7 Behavior when withdrawing the release for axis container rotation.......................................... 113
2.2.4.8 Supplementary conditions......................................................................................................... 115
2.2.5 Lead link axes ........................................................................................................................... 118
2.2.5.1 General information................................................................................................................... 118
2.2.5.2 Parameterization ....................................................................................................................... 119
2.2.5.3 System variables to enter a leading value ................................................................................ 120
2.2.5.4 Supplementary conditions......................................................................................................... 121
2.2.5.5 Example .................................................................................................................................... 121
2.2.6 System of units within a link group............................................................................................ 121
Extended Functions
Contents
2.3 Examples ...................................................................................................................................122

2.3.1 Link axis .....................................................................................................................................122
2.3.2 Axis container coordination........................................................................................................123
2.3.2.1 Axis container rotation without a part program wait...................................................................123
2.3.2.2 Axis container rotation with an implicit part program wait..........................................................124
2.3.2.3 Axis container rotation by one channel only (e.g. during power up)..........................................124
2.3.3 Evaluating axis container system variables ...............................................................................124
2.3.3.1 Conditional branch .....................................................................................................................124
2.3.3.2 Static synchronized action with $AN_AXCTSWA ......................................................................124
2.3.3.3 Wait for certain completion of axis container rotation ................................................................125
2.3.4 Configuration of a multi-spindle turning machine.......................................................................126
2.3.5 Lead link axis .............................................................................................................................135
2.3.5.1 Configuration..............................................................................................................................135
2.3.5.2 Programming..............................................................................................................................137
2.4 Data lists ....................................................................................................................................138
2.4.1 Machine data..............................................................................................................................138
2.4.1.1 General machine data................................................................................................................138
2.4.1.2 Channelspecific machine data ...................................................................................................138
2.4.1.3 Axis/spindlespecific machine data .............................................................................................139
2.4.2 Setting data ................................................................................................................................139
2.4.2.1 General setting data...................................................................................................................139
2.4.2.2 Axis/spindle-specific setting data ...............................................................................................139
2.4.3 Signals .......................................................................................................................................139
2.4.3.1 Signals from NC.........................................................................................................................139
2.4.3.2 Signals from HMI/PLC ...............................................................................................................140
2.4.3.3 General online interface.............................................................................................................140
2.4.3.4 Signals from axis/spindle ...........................................................................................................142
2.4.4 System variables........................................................................................................................142
3 H1: Manual and handwheel travel ......................................................................................................... 143
3.1 Introduction ................................................................................................................................143
3.1.1 Overview ....................................................................................................................................143
3.1.2 General characteristics when traversing in the JOG mode .......................................................144
3.1.3 Control of manual-travel functions via PLC interface.................................................................147
3.2 Continuous (JOG CONT)...........................................................................................................148
3.2.1 General functionality ..................................................................................................................148
3.2.2 Distinction between inching mode continuous mode.................................................................149
3.2.3 Supplementary conditions..........................................................................................................150
3.3 Incremental (JOG INC) ..............................................................................................................151
3.3.2 Distinction between jogging mode and continuous mode .........................................................152
3.4 Handwheel travel in JOG ...........................................................................................................154
3.4.1 Function .....................................................................................................................................154
3.4.2 Parameter assignment...............................................................................................................161
3.4.3 Travel request ............................................................................................................................166
3.4.4 Double use of the handwheel ....................................................................................................169
Extended Functions
Contents
3.5 Handwheel override in automatic mode.................................................................................... 170

3.5.1 General functionality ................................................................................................................. 170
3.5.2 Programming and activating handwheel override..................................................................... 175
3.5.3 Special features of handwheel override in automatic mode ..................................................... 177
3.6 Contour handwheel/path input using handwheel (option)......................................................... 178
3.7 DRF offset ................................................................................................................................. 180
3.8 Approaching a fixed point in JOG ............................................................................................. 183
3.8.1 Introduction ............................................................................................................................... 183
3.8.2 Functionality .............................................................................................................................. 184
3.8.3 Parameterization ....................................................................................................................... 186
3.8.4 Programming............................................................................................................................. 188
3.8.5 Supplementary Conditions ........................................................................................................ 188
3.8.6 Application example .................................................................................................................. 189
3.9 Retraction in the tool direction (JOG retract) ............................................................................ 190
3.9.1 Overview ................................................................................................................................... 190
3.9.2 Parameter assignment .............................................................................................................. 191
3.9.3 Selection.................................................................................................................................... 193
3.9.4 Tool retraction ........................................................................................................................... 195
3.9.5 Deselection ............................................................................................................................... 196
3.9.6 Repeated selection ................................................................................................................... 196
3.9.7 Continuing machining................................................................................................................ 197
3.9.8 State diagram............................................................................................................................ 198
3.9.9 System data .............................................................................................................................. 198
3.9.10 Supplementary conditions......................................................................................................... 199
3.10 Start-up: Handwheels................................................................................................................ 200
3.10.1 General information................................................................................................................... 200
3.10.2 Connection via PPU (only 828D) .............................................................................................. 201
3.10.3 Connection via PROFIBUS (828D)........................................................................................... 202
3.10.4 Connection via PROFIBUS (840D sl) ....................................................................................... 203
3.10.5 Connected via Ethernet (only 840D sl) ..................................................................................... 206
3.11 Special features relating to manual and handwheel travel ....................................................... 209
3.11.1 Manual travel of geometry/orientation axes .............................................................................. 209
3.11.2 Spindle manual travel................................................................................................................ 211
3.11.3 Monitoring functions .................................................................................................................. 213
3.11.4 Other ......................................................................................................................................... 214
3.12 Data lists.................................................................................................................................... 215
3.12.1 Machine data............................................................................................................................. 215
3.12.1.1 General machine data............................................................................................................... 215
3.12.1.2 Channel-specific machine data................................................................................................. 216
3.12.1.3 Axis/spindlespecific machine data ............................................................................................ 216
3.12.2 Setting data ............................................................................................................................... 217
3.12.2.1 General setting data.................................................................................................................. 217
3.12.3 Signals....................................................................................................................................... 218
3.12.3.1 Signals from NC ........................................................................................................................ 218
3.12.3.2 Signals to mode group .............................................................................................................. 218
3.12.3.3 Signals from mode group .......................................................................................................... 218
3.12.3.4 Signals to channel..................................................................................................................... 219
3.12.3.5 Signals from channel................................................................................................................. 220
Extended Functions
Contents
3.12.3.6 Signals to axis/spindle ...............................................................................................................221

3.12.4 System variable..........................................................................................................................222
3.12.4.1 System variable..........................................................................................................................222
3.12.5 OPI variable ...............................................................................................................................222
3.12.5.1 OPI variable ...............................................................................................................................222
4 K3: Compensations ............................................................................................................................... 223
4.1 Introduction ................................................................................................................................223
4.2 Temperature compensation .......................................................................................................224
4.2.1 Description of functions..............................................................................................................224
4.2.2 Commissioning...........................................................................................................................227
4.2.3 Example .....................................................................................................................................229
4.2.3.1 Commissioning the temperature compensation for the Z axis of a lathe ..................................229
4.3 Backlash compensation .............................................................................................................231
4.3.1 Mechanical backlash compensation ..........................................................................................231
4.3.1.1 Description of functions..............................................................................................................231
4.3.1.2 Commissioning...........................................................................................................................233
4.3.2 Dynamic backlash compensation ..............................................................................................234
4.3.2.2 Commissioning...........................................................................................................................235
4.4 Interpolatory compensation........................................................................................................235
4.4.1 General properties .....................................................................................................................235
4.4.2 Compensation of leadscrew errors and measuring system errors ............................................238
4.4.2.1 Measuring system error compensation (MSEC)........................................................................238
4.4.2.2 Commissioning...........................................................................................................................239
4.4.2.3 Example .....................................................................................................................................242
4.4.3 Compensation of sag and angularity errors...............................................................................243
4.4.3.2 Commissioning...........................................................................................................................247
4.4.3.3 Examples ...................................................................................................................................251
4.4.4 Direction-dependent leadscrew error compensation .................................................................259
4.4.4.2 Commissioning...........................................................................................................................260
4.4.4.3 Example .....................................................................................................................................264
4.4.5 Extension of the sag compensation with NCU link - only 840D sl .............................................267
4.4.6 Special features of interpolatory compensation.........................................................................277
4.5 Dynamic feedforward control (following error compensation) ...................................................278
4.5.1 General properties .....................................................................................................................278
4.5.2 Speed feedforward control.........................................................................................................280
4.5.3 Torque feedforward control........................................................................................................282
4.5.4 Dynamic response adaptation ...................................................................................................283
4.5.5 Forward feed control for command- and PLC axes ...................................................................284
4.5.6 Secondary conditions.................................................................................................................286
4.6 Friction compensation (quadrant error compensation) ..............................................................287
4.6.1 General function description ......................................................................................................287
4.6.3 Friction compensation with a constant compensation value .....................................................288
4.6.3.1 Function activation .....................................................................................................................288
4.6.3.2 commissioning ...........................................................................................................................289
Extended Functions
Contents
4.6.4 Friction compensation with acceleration-dependent compensation value ............................... 294

4.6.4.1 Description of functions............................................................................................................. 294
4.6.4.2 Function activation .................................................................................................................... 295
4.6.4.3 commissioning .......................................................................................................................... 295
4.6.5 Compensation value for short traversing blocks ....................................................................... 296
4.7 Measures for hanging (suspended axes).................................................................................. 297
4.7.1 Electronic counterweight ........................................................................................................... 297
4.7.2 Reboot delay ............................................................................................................................. 299
4.8 Data lists.................................................................................................................................... 301
4.8.1 Machine data............................................................................................................................. 301
4.8.1.2 Channelspecific machine data .................................................................................................. 301
4.8.2 Setting data ............................................................................................................................... 302
4.8.2.2 Axis/spindle-specific setting data .............................................................................................. 303
4.8.3 Signals....................................................................................................................................... 303
4.8.3.1 Signals from NC ........................................................................................................................ 303
4.8.3.2 Signals from mode group .......................................................................................................... 303
4.8.3.4 Signals to axis/spindle............................................................................................................... 303
4.8.3.5 Signals from axis/spindle .......................................................................................................... 304
5 K5: Mode groups, channels, axis interchange ....................................................................................... 305
5.1 Brief description ........................................................................................................................ 305
5.2 Mode groups - only 840D sl ...................................................................................................... 306
5.3 Channels - only 840D sl ............................................................................................................ 307
5.3.1 Channel synchronization (program coordination) ..................................................................... 308
5.3.2 Channel synchronization: Conditional wait in path controlled operation .................................. 311
5.3.3 Running-in channel-by-channel ................................................................................................ 315
5.4 Axis/spindle replacement .......................................................................................................... 320
5.4.1 Introduction ............................................................................................................................... 320
5.4.2 Example of an axis replacement............................................................................................... 322
5.4.3 Axis replacement options .......................................................................................................... 323
5.4.4 Replacement behavior NC program ......................................................................................... 324
5.4.5 Transition the axis into the neutral state (RELEASE) ............................................................... 325
5.4.6 Transferring an axis or spindle into the part program (GET, GETD) ........................................ 326
5.4.7 Automatic axis replacement ...................................................................................................... 327
5.4.8 Axis replacement via PLC ......................................................................................................... 329
5.4.9 Set axis replacement behavior variable. ................................................................................... 332
5.4.10 Axis interchange via axis container rotation.............................................................................. 333
5.4.11 Axis replacement with and without preprocessing stop ............................................................ 333
5.4.12 Axis exclusively controlled from the PLC .................................................................................. 335
5.4.13 Axis permanently assigned to the PLC ..................................................................................... 336
5.4.14 Geometry axis in rotated frame and axis replacement ............................................................. 337
5.4.15 Axis replacement from synchronized actions............................................................................ 338
5.4.16 Axis interchange for leading axes (gantry)................................................................................ 341
5.5 Marginal conditions ................................................................................................................... 341
Extended Functions
Contents
5.6 Data lists ....................................................................................................................................343

5.6.1 Machine data..............................................................................................................................343
5.6.1.2 Channel-specific machine data..................................................................................................343
5.6.2 Setting data ................................................................................................................................346
5.6.2.1 Channelspecific setting data ......................................................................................................346
5.6.3 Signals .......................................................................................................................................346
5.6.3.1 Signals to/from BAG ..................................................................................................................346
5.6.3.2 Signals to/from Channel.............................................................................................................346
6 M1: Kinematic transformation ................................................................................................................ 347
6.1 Brief description .........................................................................................................................347
6.1.1 TRANSMIT (option) ...................................................................................................................347
6.1.2 TRACYL (option)........................................................................................................................348
6.1.3 TRAANG (option).......................................................................................................................349
6.1.4 Chained transformations............................................................................................................349
6.1.5 Activating transformation machine data via parts program/softkey ...........................................350
6.2 TRANSMIT face end transformation (option) ............................................................................350
6.2.1 Specific settings .........................................................................................................................351
6.2.2 Switch on....................................................................................................................................354
6.2.3 Deactivation ...............................................................................................................................354
6.2.4 Applications................................................................................................................................355
6.2.5 Working area limitations.............................................................................................................361
6.2.6 Overlaid motions with TRANSMIT .............................................................................................362
6.2.7 Monitoring of rotary axis rotations over 360 .............................................................................362
6.2.8 Constraints .................................................................................................................................362
6.2.9 Example: Axis configuration.......................................................................................................363
6.3 TRACYL cylinder surface transformation (option) .....................................................................366
6.3.1 Preconditions .............................................................................................................................368
6.3.3 Switch on....................................................................................................................................375
6.3.4 Deactivation ...............................................................................................................................376
6.3.5 Boundary conditions ..................................................................................................................376
6.4 TRAANG oblique angle transformation (option) ........................................................................378
6.4.1 Preconditions .............................................................................................................................379
6.4.3 Switch on....................................................................................................................................383
6.4.4 Deactivation ...............................................................................................................................383
6.4.5 Boundary conditions ..................................................................................................................384
6.4.6 Programming (G05, G07) ..........................................................................................................385
6.5 Chained transformations............................................................................................................387
6.5.1 Activating chained transformations............................................................................................389
6.5.2 Switching off a chained transformation......................................................................................389
6.5.3 Special characteristics of chained transformations....................................................................389
6.5.4 Persistent transformation ...........................................................................................................390
6.5.5 Axis positions in the transformation chain .................................................................................395
6.6 Cartesian PTP travel..................................................................................................................398
6.6.1 Programming of position ............................................................................................................401
6.6.2 Overlap areas of axis angles .....................................................................................................402
Extended Functions
Contents
6.6.3 Examples of ambiguities of position.......................................................................................... 403

6.6.4 Example of ambiguity in rotary axis position............................................................................. 404
6.6.5 PTP/CP switchover in JOG mode............................................................................................. 404
6.7 Cartesian manual travel (optional) ............................................................................................ 405
6.8 Activating transformation machine data via part program/softkey ............................................ 412
6.8.1 Functionality .............................................................................................................................. 412
6.8.2 Constraints ................................................................................................................................ 413
6.8.3 Control response to power ON, mode change, RESET, block search, REPOS ...................... 415
6.8.4 List of machine data affected .................................................................................................... 415
6.9 Constraints ................................................................................................................................ 418
6.9.1 Chained transformations ........................................................................................................... 418
6.10 Examples................................................................................................................................... 419
6.10.1 TRANSMIT ................................................................................................................................ 419
6.10.2 TRACYL .................................................................................................................................... 420
6.10.3 TRAANG ................................................................................................................................... 426
6.10.4 Chained transformations ........................................................................................................... 427
6.10.5 Activating transformation MD via a part program...................................................................... 431
6.10.6 Axis positions in the transformation chain................................................................................. 432
6.11 Data lists.................................................................................................................................... 435
6.11.1 Machine data............................................................................................................................. 435
6.11.1.1 TRANSMIT ................................................................................................................................ 435
6.11.1.2 TRACYL .................................................................................................................................... 436
6.11.1.3 TRAANG ................................................................................................................................... 438
6.11.1.4 Chained transformations ........................................................................................................... 439
6.11.1.5 Non transformation-specific machine data................................................................................ 439
6.11.2 Signals....................................................................................................................................... 439
7 M5: Measurement.................................................................................................................................. 441
7.2 Hardware requirements............................................................................................................. 442
7.2.1 Probes that can be used ........................................................................................................... 442
7.3 Channel-specific measuring...................................................................................................... 444
7.3.1 Measurement ............................................................................................................................ 444
7.3.2 Measurement results................................................................................................................. 445
7.4 Axial measurement ................................................................................................................... 446
7.4.1 Measurement ............................................................................................................................ 446
7.4.2 Telegram selection.................................................................................................................... 449
7.4.3 Measurement results................................................................................................................. 449
7.5 Setting zeros, workpiece measuring and tool measuring ......................................................... 451
7.5.1 Preset actual value memory and scratching ............................................................................. 451
7.5.2 Workpiece measuring ............................................................................................................... 452
7.5.2.1 Input values............................................................................................................................... 452
7.5.2.2 Measurement selection ............................................................................................................. 459
7.5.2.3 Output values ............................................................................................................................ 460
7.5.2.4 Calculation method ................................................................................................................... 461
7.5.2.5 Units of measurement and measurement variables for the calculation.................................... 464
7.5.2.6 Diagnostics................................................................................................................................ 465
Extended Functions
Contents
7.5.3 Types of workpiece measurement.............................................................................................466

7.5.3.1 Measurement of an edge (measurement type 1, 2, 3) ..............................................................466
7.5.3.2 Measurement of an angle (measurement type 4, 5, 6, 7)..........................................................470
7.5.3.3 Measurement of a hole (measurement type 8)..........................................................................473
7.5.3.4 Measurement of a shaft (measurement type 9).........................................................................476
7.5.3.5 Measurement of a groove (measurement type 12)....................................................................477
7.5.3.6 Measurement of a web (measurement type 13) ........................................................................480
7.5.3.7 Measurement of geo axes and special axes (measurement type 14, 15).................................481
7.5.3.8 Measurement of an oblique edge (measurement type 16)........................................................483
7.5.3.9 Measurement of an oblique angle in a plane (measurement type 17) ......................................485
7.5.3.10 Redefine measurement around a WCS reference frame (measurement type 18)....................488
7.5.3.11 Measurement of a 1-, 2- and 3-dimensional setpoint selection (measurement type 19, 20,
21) ..............................................................................................................................................492
7.5.3.12 Measuring a measuring point in any coordinate system (measurement type 24) .....................496
7.5.3.13 Measurement of a rectangle (measurement type 25)................................................................500
7.5.3.14 Measurement for saving data management frames (measurement type 26)............................501
7.5.3.15 Measurement for restoring backed-up data management frames (measurement type 27) ......502
7.5.3.16 Measurement for defining an additive rotation for taper turning (measurement type 28)..........503
7.5.4 Tool measuring ..........................................................................................................................504
7.5.5 Types of workpiece measurement.............................................................................................505
7.5.5.1 Measurement of tool lengths (measurement type 10) ...............................................................505
7.5.5.2 Measurement of tool diameter (measurement type 11).............................................................507
7.5.5.3 Measurement of tool lengths with zoom-in function (measurement type 22) ............................508
7.5.5.4 Measuring a tool length with stored or current position (measurement type 23).......................509
7.5.5.5 Measurement of a tool length of two tools with the following orientation: .................................511
7.6 Measurement accuracy and functional testing ..........................................................................523
7.6.1 Measurement accuracy..............................................................................................................523
7.6.2 Probe function test .....................................................................................................................524
7.7 Simulated measuring .................................................................................................................525
7.7.2 Position-related switch request ..................................................................................................525
7.7.3 External switch request..............................................................................................................527
7.7.4 System variable..........................................................................................................................528
7.8 Channels - only 840D sl.............................................................................................................528
7.8.1 Measuring mode 1 .....................................................................................................................528
7.8.2 Measuring mode 2 .....................................................................................................................529
7.8.3 Continuous measurement..........................................................................................................529
7.8.4 Functional test and repeat accuracy..........................................................................................531
7.9 Data lists ....................................................................................................................................532
7.9.1 Machine data..............................................................................................................................532
7.9.1.2 Channel-specific machine data..................................................................................................533
8 N3: Software cams, position switching cycles - only 840D sl ................................................................. 535
8.1 Brief Description.........................................................................................................................535
8.2 Cam signals and cam positions .................................................................................................536
8.2.1 Generation of cam signals for separate output..........................................................................536
8.2.2 Generation of cam signals with gated output.............................................................................539
Extended Functions
Contents
8.2.3 Cam positions ........................................................................................................................... 543

8.2.4 Lead/delay times (dynamic cam) .............................................................................................. 545
8.3 Output of cam signals ............................................................................................................... 546
8.3.1 Activating................................................................................................................................... 546
8.3.2 Output of cam signals to PLC ................................................................................................... 547
8.3.3 Output of cam signals to NCK I/Os in position control cycle..................................................... 547
8.3.4 Timer-controlled cam signal output........................................................................................... 549
8.3.5 Independent, timer-controlled output of cam signals ................................................................ 550
8.4 Position-time cams.................................................................................................................... 551
8.5 Supplementary Conditions ........................................................................................................ 553
8.6 Data lists.................................................................................................................................... 553
8.6.1 Machine data............................................................................................................................. 553
8.6.2 Setting data ............................................................................................................................... 554
8.6.3 Signals....................................................................................................................................... 554
9 N4: Own channel - only 840D sl ............................................................................................................ 555
9.1 Brief Description........................................................................................................................ 555
9.2 Stroke control ............................................................................................................................ 555
9.2.2 High-speed signals.................................................................................................................... 556
9.2.3 Criteria for stroke initiation ........................................................................................................ 558
9.2.4 Axis start after punching............................................................................................................ 560
9.2.5 PLC signals specific to punching and nibbling.......................................................................... 561
9.2.6 Punching and nibbling-specific reactions to standard PLC signals .......................................... 561
9.2.7 Signal monitoring ...................................................................................................................... 562
9.3 Activation and deactivation ....................................................................................................... 562
9.3.1 Language commands................................................................................................................ 562
9.3.2 Functional expansions .............................................................................................................. 567
9.3.3 Compatibility with earlier systems............................................................................................. 571
9.4 Automatic path segmentation.................................................................................................... 573
9.4.2 Operating characteristics with path axes .................................................................................. 575
9.4.3 Response in connection with single axes ................................................................................. 579
9.5 Rotatable tool ............................................................................................................................ 584
9.5.2 Coupled motion of punch and die ............................................................................................. 585
9.5.3 Tangential control...................................................................................................................... 586
9.6 Protection zones ....................................................................................................................... 590
9.7 Supplementary conditions......................................................................................................... 590
9.8 Examples................................................................................................................................... 591
9.8.1 Examples of defined start of nibbling operation ........................................................................ 591
Extended Functions
Contents
9.9 Data lists ....................................................................................................................................596

9.9.1 Machine data..............................................................................................................................596
9.9.2 Setting data ................................................................................................................................596
9.9.2.1 Channelspecific setting data ......................................................................................................596
9.9.3 Signals .......................................................................................................................................597
9.9.3.1 Signals to channel......................................................................................................................597
9.9.3.2 Signals from channel .................................................................................................................597
9.9.4 Language commands ................................................................................................................597
10 P2: Positioning axes .............................................................................................................................. 599
10.1 Product brief...............................................................................................................................599
10.2 Own channel, positioning axis or concurrent positioning axis ...................................................601
10.2.1 Own channel - only 840D sl .......................................................................................................602
10.2.2 Positioning axis ..........................................................................................................................602
10.2.3 Concurrent positioning axis........................................................................................................605
10.3 Motion behavior and interpolation functions ..............................................................................606
10.3.1 Path interpolator and axis interpolator .......................................................................................606
10.3.2 Interpolation response of path axis in G0 ..................................................................................606
10.3.3 Autonomous singleaxis operations ............................................................................................608
10.3.4 Autonomous single-axis functions with NC-controlled ESR ......................................................613
10.4 Positioning axis dynamic response............................................................................................615
10.5 Programming..............................................................................................................................617
10.5.1 General ......................................................................................................................................617
10.5.2 Revolutional feed rate in external programming ........................................................................620
10.6 Block change..............................................................................................................................621
10.6.1 Settable block change time........................................................................................................623
10.6.2 End of motion criterion with block search ..................................................................................628
10.7 Control by the PLC.....................................................................................................................629
10.7.1 Starting concurrent positioning axes from the PLC ...................................................................631
10.7.2 PLC-controlled axes...................................................................................................................632
10.7.3 Control response of PLC-controlled axes ..................................................................................633
10.8 Response with special functions................................................................................................635
10.8.1 Dry run (DRY RUN) ...................................................................................................................635
10.8.2 Single block................................................................................................................................635
10.9 Examples ...................................................................................................................................636
10.9.1 Motion behavior and interpolation functions ..............................................................................636
10.9.1.1 Traversing path axes without interpolation with G0 ...................................................................637
10.10 Data lists ....................................................................................................................................637
10.10.1 Machine data..............................................................................................................................637
10.10.1.1 NC-specific machine data.....................................................................................................637
10.10.1.2 Channelspecific machine data..............................................................................................637
10.10.1.3 Axis/spindlespecific machine data ........................................................................................638
10.10.2 Setting data ................................................................................................................................638
10.10.2.1 Axis/spindle-specific setting data..........................................................................................638
Extended Functions
Contents
10.10.3 Signals....................................................................................................................................... 638

10.10.3.1 Signals to channel................................................................................................................ 638
10.10.3.2 Signals from channel ........................................................................................................... 639
10.10.3.3 Signals to axis/spindle ......................................................................................................... 639
10.10.3.4 Signals from axis/spindle ..................................................................................................... 639
11 P5: Oscillation - only 840D sl ................................................................................................................. 641
11.2 Asynchronous oscillation........................................................................................................... 642
11.2.1 Influences on asynchronous oscillation .................................................................................... 643
11.2.2 Asynchronous oscillation under PLC control ............................................................................ 650
11.2.3 Special reactions during asynchronous oscillation ................................................................... 650
11.3 Oscillation controlled by synchronized actions ......................................................................... 653
11.3.1 Infeed at reversal point 1 or 2 ................................................................................................... 656
11.3.2 Infeed in reversal point range.................................................................................................... 657
11.3.3 Infeed at both reversal points.................................................................................................... 659
11.3.4 Stop oscillation movement at the reversal point ....................................................................... 660
11.3.5 Oscillation movement restarting................................................................................................ 661
11.3.6 Do not start partial infeed too early ........................................................................................... 662
11.3.7 Assignment of oscillation and infeed axes OSCILL .................................................................. 662
11.3.8 Definition of infeeds POSP........................................................................................................ 663
11.3.9 External oscillation reversal ...................................................................................................... 664
11.4 Marginal conditions ................................................................................................................... 665
11.5 Examples................................................................................................................................... 665
11.5.1 Example of asynchronous oscillation........................................................................................ 666
11.5.2 Example 1 of oscillation with synchronized actions .................................................................. 667
11.5.3 Example 2 of oscillation with synchronized actions .................................................................. 670
11.5.4 Examples for starting position ................................................................................................... 672
11.5.4.1 Define starting position via language command ....................................................................... 672
11.5.4.2 Start oscillation via setting data ................................................................................................ 672
11.5.4.3 Non-modal oscillation (starting position = reversal point 1) ...................................................... 673
11.5.5 Example of external oscillation reversal.................................................................................... 676
11.5.5.1 Change reversal position via synchronized action with "external oscillation reversal" ............. 676
11.6 Data lists.................................................................................................................................... 676
11.6.1 Machine data............................................................................................................................. 676
11.6.2 Setting data ............................................................................................................................... 677
11.6.2.1 Axis/spindle-specific setting data .............................................................................................. 677
11.6.3 Signals....................................................................................................................................... 677
11.6.4 System variables....................................................................................................................... 678
11.6.4.1 Main run variables for motion-synchronous actions ................................................................. 678
12 R2: Rotary axes ..................................................................................................................................... 681
12.2 Modulo 360 degrees ................................................................................................................. 685
Extended Functions
Contents
12.3 Programming rotary axes...........................................................................................................688

12.3.1 General information ...................................................................................................................688
12.3.2 Rotary axis with active modulo conversion (continuously-turning rotary axis). .........................688
12.3.3 Rotary axis without modulo conversion .....................................................................................694
12.3.4 Other programming features relating to rotary axes ..................................................................696
12.4 Activating rotary axes.................................................................................................................697
12.5 Special features of rotary axes ..................................................................................................698
12.6 Examples ...................................................................................................................................699
12.7 Data lists ....................................................................................................................................700
12.7.1 Machine data..............................................................................................................................700
12.7.2 Setting data ................................................................................................................................700
12.7.2.2 Axis/spindle-specific setting data ...............................................................................................700
12.7.3 Signals .......................................................................................................................................701
12.7.3.1 Signals to axis/spindle ...............................................................................................................701
13 S3: Synchronous spindle ....................................................................................................................... 703
13.1 Brief description .........................................................................................................................703
13.1.1 Function .....................................................................................................................................703
13.1.2 Synchronous mode ....................................................................................................................705
13.1.3 Prerequisites for synchronous mode .........................................................................................711
13.1.4 Selecting synchronous mode for a part program.......................................................................712
13.1.5 Deselecting the synchronous mode for the part program..........................................................714
13.1.6 Controlling synchronous spindle coupling via PLC....................................................................716
13.1.7 Monitoring of synchronous operation.........................................................................................718
13.2 Programming..............................................................................................................................720
13.2.1 Definition (COUPDEF) ...............................................................................................................721
13.2.2 Switch the coupling (COUPON, COUPONC, COUPOF) on and off..........................................724
13.2.3 Axial system variables for synchronous spindle ........................................................................726
13.2.4 Automatic selection and deselection of position control ............................................................727
13.3 Configuration..............................................................................................................................728
13.3.1 Response of the synchronous-spindle coupling for NC Start ....................................................729
13.3.2 Behavior of the synchronous-spindle coupling for reset............................................................729
13.4 Points to note .............................................................................................................................730
13.4.1 Special features of synchronous mode in general.....................................................................730
13.4.2 Restore synchronism of following spindle..................................................................................732
13.4.3 Synchronous mode and NC/PLC interface signals....................................................................734
13.4.4 Differential speed between leading and following spindles .......................................................738
13.4.5 Behavior of synchronism signals during synchronism correction ..............................................743
13.4.6 Delete synchronism correction and NC reset ............................................................................743
13.4.7 Special points regarding start-up of a synchronous spindle coupling........................................743
13.5 Boundary conditions ..................................................................................................................749
13.6 Examples ...................................................................................................................................749
Extended Functions
Contents
13.7 Data lists.................................................................................................................................... 750

13.7.1 Machine data............................................................................................................................. 750
13.7.1.1 NC-specific machine data ......................................................................................................... 750
13.7.2 Setting data ............................................................................................................................... 751
13.7.2.1 Channelspecific setting data ..................................................................................................... 751
13.7.3 Signals....................................................................................................................................... 752
13.7.3.1 Signals to channel..................................................................................................................... 752
13.7.4 System variables....................................................................................................................... 753
14 S7: Memory configuration ...................................................................................................................... 755
14.2 Memory organization................................................................................................................. 756
14.2.1 Active and passive file system .................................................................................................. 756
14.2.2 Reconfiguration ......................................................................................................................... 757
14.3 Configuration of the static user memory ................................................................................... 758
14.3.1 Division of the static NC memory.............................................................................................. 758
14.3.2 Commissioning.......................................................................................................................... 761
14.4 Configuration of the dynamic user memory .............................................................................. 762
14.4.1 Division of the dynamic NC memory......................................................................................... 762
14.4.2 Commissioning.......................................................................................................................... 763
14.5 Data lists.................................................................................................................................... 764
14.5.1 Machine data............................................................................................................................. 764
15 T1: Indexing axes .................................................................................................................................. 771
15.2 Traversing of indexing axes ...................................................................................................... 771
15.2.1 Traversing of indexing axes in the JOG mode.......................................................................... 772
15.2.2 Traversing of indexing axes in the AUTOMATIC mode............................................................ 774
15.2.3 Traversing of indexing axes by PLC ......................................................................................... 775
15.3 Parameterization of indexing axes............................................................................................ 775
15.4 Programming of indexing axes.................................................................................................. 777
15.5 Equidistant index intervals ........................................................................................................ 782
15.5.1 Features .................................................................................................................................... 782
15.5.2 Hirth tooth system ..................................................................................................................... 783
15.5.3 Response of the Hirth axes in particular situations................................................................... 784
15.5.4 Restrictions ............................................................................................................................... 785
15.5.5 Modified activation of machine data.......................................................................................... 786
15.6 Starting up indexing axes.......................................................................................................... 786
15.7 Special features of indexing axes ............................................................................................. 790
Extended Functions
Contents
15.8 Examples ...................................................................................................................................791

15.8.1 Examples of equidistant indexes ...............................................................................................791
15.9 Data lists ....................................................................................................................................793
15.9.1 Machine data..............................................................................................................................793
15.9.2 Setting data ................................................................................................................................793
15.9.3 Signals .......................................................................................................................................794
16 W3: Tool change.................................................................................................................................... 795
16.1 Brief Description.........................................................................................................................795
16.2 Tool magazines and tool change equipments ...........................................................................795
16.3 Tool change times......................................................................................................................796
16.4 Cut-to-cut time............................................................................................................................796
16.5 Starting the tool change .............................................................................................................796
16.6 Tool change point ......................................................................................................................797
16.7 Supplementary Conditions.........................................................................................................798
16.8 Examples ...................................................................................................................................798
16.9 Data lists ....................................................................................................................................800
16.9.1 Machine data..............................................................................................................................800
16.9.1.3 Axis-/spindlespecific machine data............................................................................................800
16.9.2 Signals .......................................................................................................................................800
16.9.2.1 Signals from channel .................................................................................................................800
17 W4: Grinding-specific tool offset and tool monitoring ............................................................................. 801
17.1 Tool offset for grinding operations .............................................................................................801
17.1.1 Structure of tool data..................................................................................................................801
17.1.2 Edge-specific offset data............................................................................................................803
17.1.3 Tool-specific grinding data .........................................................................................................806
17.1.4 Examples of grinding tools.........................................................................................................812
17.2 Online tool offset ........................................................................................................................816
17.2.2 Write online tool offset: Continuous ...........................................................................................818
17.2.3 Activate/deactivate online tool offset .........................................................................................820
17.2.4 Example of writing online tool offset continuously .....................................................................821
17.2.5 Write online tool offset discretely ...............................................................................................823
17.2.6 Information about online offsets.................................................................................................823
17.3 Online tool radius compensation................................................................................................824
17.4 Grinding-specific tool monitoring................................................................................................825
17.4.2 Geometry monitoring .................................................................................................................826
Extended Functions
Contents
17.4.3 Speed monitoring ...................................................................................................................... 827

17.4.4 Selection/deselection of tool monitoring ................................................................................... 828
17.5 Constant grinding wheel peripheral speed (GWPS). ................................................................ 829
17.5.2 Selection/deselection and programming of GWPS, system variable ....................................... 830
17.5.3 GWPS in all operating modes................................................................................................... 831
17.5.4 Programming example for GWPS............................................................................................. 832
17.6 Supplementary Conditions ........................................................................................................ 833
17.6.1 Tool changes with online tool offset.......................................................................................... 833
17.7 Data lists.................................................................................................................................... 834
17.7.1 Machine data............................................................................................................................. 834
17.7.2 Signals....................................................................................................................................... 834
18 Z2: NC/PLC interface signals................................................................................................................. 835
18.1 Digital and analog NCK I/Os (A4) ............................................................................................. 835
18.1.1 Signals to NC (DB10)................................................................................................................ 835
18.1.2 Signals from NC (DB10)............................................................................................................ 843
18.2 Distributed systems (B3) ........................................................................................................... 846
18.2.1 Defined logical functions/defines .............................................................................................. 846
18.2.2 Interfaces in DB19 for M:N........................................................................................................ 849
18.2.4 Signals from axis/spindle (DB31, ...)......................................................................................... 857
18.3 Manual and Handwheel Travel (H1) ......................................................................................... 858
18.3.2 Signals to channel (DB21, ...) ................................................................................................... 861
18.3.3 Signals from channel (DB21, ...) ............................................................................................... 867
18.3.4 Signals with contour handwheel ............................................................................................... 874
18.3.5 Signals to axis/spindle (DB31, ...) ............................................................................................. 876
18.4 Compensations (K3) ................................................................................................................. 884
18.5 Mode Groups, Channels, Axis Replacement (K5) .................................................................... 885
18.6 Kinematic Transformation (M1)................................................................................................. 886
18.6.1 Signals from channel (DB21, ...) ............................................................................................... 886
18.7 Measurement (M5).................................................................................................................... 887
18.8 Software cams, position switching signals (N3)........................................................................ 888
18.8.1 Signal overview ......................................................................................................................... 888
Extended Functions
Contents
18.9 Punching and Nibbling (N4) .......................................................................................................891

18.9.1 Signal overview ..........................................................................................................................891
18.9.2 Signals to channel (DB21, ...) ....................................................................................................891
18.9.3 Signals from channel (DB21, ...) ................................................................................................893
18.10 Positioning axes (P2) .................................................................................................................894
18.10.1 Signals to axis/spindle (DB31, ...) ..............................................................................................894
18.10.2 Function call - only 840D sl........................................................................................................898
18.11 Oscillation (P5)...........................................................................................................................898
18.11.2 Signals from axis/spindle (DB31, ...)..........................................................................................900
18.12 Rotary axes (R2)........................................................................................................................902
18.13 Synchronous Spindles (S3) .......................................................................................................903
18.14 Memory Configuration (S7)........................................................................................................906
18.15 Indexing Axes (T1).....................................................................................................................906
18.16 Tool Change (W3)......................................................................................................................907
18.17 Grinding-specific tool offset and tool monitoring (W4)...............................................................908
A Appendix................................................................................................................................................ 909
A.1 List of abbreviations ...................................................................................................................909
A.2 Overview ....................................................................................................................................918
Glossary ................................................................................................................................................ 919
Index...................................................................................................................................................... 941
Extended Functions
Contents
Extended Functions
A4: Digital and analog NCK I/Os for SINUMERIK
840D sl 1
1.1 Introduction
Function
Signals can be read and output in the interpolation cycle via the inputs/outputs of the fast
digital and analog NCK I/Os. The following functions can be executed with these signals, for
example:
Several feedrate values in one block
Several auxiliary functions in one block
Rapid retraction on final dimension
Axis-specific delete distance-to-go
Program branches
Rapid NC Start
Analog calipers
Position switching signals
Punching/nibbling functions
Analog-value control
Hardware
The SINUMERIK 840D sl hardware has three 14-pin I/O interfaces X122, X132 and X142 on
the NCU on-board. Only X142 is available as a fast NCK I/O.
There are four fast digital inputs and four outputs on the X142 that can be addressed via the
first address byte and via the $A_IN[1...4] and $A_OUT[1...4] system variables.
ET 200 modules can also be connected to the PROFIBUS DP/MPI interfaces X126 and
X136. This enables the number of digital and analog NCK I/Os to be expanded by 32 and 8
respectively. These NCK I/Os are called external NCK I/Os in the following.
Extended Functions
A4: Digital and analog NCK I/Os for SINUMERIK 840D sl
1.1 Introduction
Table 1- 1 Maximum number of digital and analog NCK I/Os
Total NCU on-board External NCK I/Os

Digital inputs 36 4 32
Digital outputs 36 4 32
Analog inputs 8 - 8
Analog outputs 8 - 8
References:
For further information about the hardware specification, refer to:
SINUMERIK 840D sl NCU Manual
SIMATIC ET 200S FC Operating Instructions
Access to NCK I/Os:

The fast digital and analog NCK I/Os can be accessed in the following ways:
Access via PLC (Page 27) (for on-board I/Os and PROFIBUS I/Os)
Access via PROFIBUS (Page 54) (for PROFIBUS I/Os)
Monitoring
The following monitoring functions are active for the external NCK I/Os:
During run-up:
Check whether the arrangement of components of the I/O modules in the ET 200
modules matches the MD assignments.
During cyclic operation:
Sign-of-life monitoring in interpolation cycles
Module monitoring in interpolation cycles
Temperature monitoring
In the event of a fault, NC-Ready is canceled and an alarm is output.
Response to faults
The digital and analog NCK outputs are switched to a safe status (0 V at output) in the event
of faults (e.g. NC-Ready = 0) in the NCU or power failures.
Extended Functions
1.2 Access via PLC
1.2 Access via PLC
1.2.1 Brief description
Configuring NCK I/Os

During commissioning, the number and the hardware assignment of the addressable digital
and analog NCK I/Os and their assignment to NC functions is defined via machine data.
For further information, see "Configuration of the NCK I/Os (Page 28)".
Data exchange
The signals and analog values of the digital and analog I/Os are available in the NC (part
program, ASUB, synchronized action, etc.) in the form of system variables.
$A_IN [<n>] Read digital NCK input <n> (where <n> = 1...4 and 9...40)
For further information, see "NCK digital inputs (Page 31)".
$A_OUT [<n>] Read/write digital NCK output <n> (where <n> = 1...4 and 9...40)
For further information, see "NCK digital outputs (Page 32)".
$A_INA [<n>] Read analog NCK input <n> read (where <n> = 1...8)
For further information, see "NCK analog inputs (Page 37)".
$A_OUTA [<n>] Read/write analog NCK output <n> read (where <n> = 1...8)
For further information, see "NCK analog outputs (Page 39)".
<n> = number of the NCK input/output
Note
When these system variables are read by the part program, a preprocessing stop (STOPRE)
is initiated inside the control.
Comparator inputs
In addition to the digital and analog NCK inputs, 16 internal comparator inputs (comparator
input bytes 1 and 2) are also available.
The signal state of a comparator input is formed by comparing an analog input signal with a
threshold value within a setting data.
For further information, see "Comparator inputs (Page 45)".
Extended Functions
1.2 Access via PLC
PLC I/Os for direct addressing by NCK

Up to 32 bytes for digital input signals and analog input values, and up to 32 bytes for digital
output signals and analog output values can be addressed directly by the part program.
These bytes must be taken into account when the PLC is configured. They are processed
directly by the PLC operating system. As a result, the time taken to transfer signals between
the NC and PLC I/O modules is of an order of magnitude of 0.5 ms.
Note
The output bytes specified for the NCK may not be write-accessed by the PLC user program,
as the access operations between the NCK and PLC would be uncoordinated.
For further information, see "Direct PLC I/Os, addressable from the NC (Page 48)".
1.2.2 Configuration of the NCK I/Os
Number of active NCK I/Os

The number of addressable digital NCK I/O bytes and analog I/Os is defined with the
machine data:
MD10350 $MN_FASTIO_DIG_NUM_INPUTS Number of active digital NCK

input bytes (max. 5)
MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS Number of active digital NCK
output bytes (max. 5)
MD10300 $MN_FASTIO_ANA_NUM_INPUTS Number of active analog NCK
inputs (max. 8)
MD10310 $MN_FASTIO_ANA_NUM_OUTPUTS Number of active analog NCK
outputs (max. 8)
Corresponding alarms are generated if the part program addresses I/Os that have not been
defined in the above machine data.
The NCK I/Os do not have to actually exist in the hardware. In this case the signal states or
the binary analog values are set to "zero" in a defined way inside the NCK. However, these
values can be changed by the PLC.
Extended Functions
1.2 Access via PLC
Hardware assignment of the external NCK I/Os

The assignment of the I/O signal modules or I/O modules to the external NCK I/Os is
performed via the machine data:
MD10366 $MN_HW_ASSIGN_DIG_FASTIN[<n>] HW assignment for external

digital inputs
MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[<n>] HW assignment for external
digital outputs
MD10362 $MN_HW_ASSIGN_ANA_FASTIN[<n>] HW assignment for external
analog inputs
MD10364 $MN_HW_ASSIGN_ANA_FASTOUT[<n>] HW assignment for external
analog outputs
<n> = Index for addressing the external digital I/O bytes (0 ... 3) or the external analog I/Os
(0 ... 7)
Example:
Two additional input bytes and one additional output byte are configured in the NC for the
data exchange with the digital I/Os of an external PROFIBUS module.
Hardware assignment:
MD10366 $MN_HW_ASSIGN_DIG_FASTIN[0]='H5000200' ; for $A_IN[9] ... [16]
MD10366 $MN_HW_ASSIGN_DIG_FASTIN[1]='H5000201' ; for $A_IN[17] ... [20]
MD10368 $MN_HW_ASSIGN_DIG_FASTOUT[0]='H5000200' ; for $A_OUT[9] ... [16]
'H5000000' specifies that the input/output is on the PROFIBUS.
The lower-order digits specify the start address of the assigned module as a logical
PROFIBUS address in hexadecimal format.
For the configuration in the SIMATIC Manager, the same logical address is assigned in
decimal format (e.g. the value 'H202' corresponds to the logical address '514').
Number of active NCK I/O bytes:
MD10350 $MN_FASTIO_DIG_NUM_INPUTS = 3
MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS = 2
Note
The on-board byte must also be counted for the configuration of MD10350 or MD10360!
Extended Functions
1.2 Access via PLC
Weighting factor for the analog NCK I/Os

The weighting factor can be used to adapt each individual NCK I/O to the AD or DA
converter of the analog I/O module used:
MD10320 $MN_FASTIO_ANA_INPUT_WEIGHT[<n>] Weighting factor for the analog

NCK inputs
For further information, see
"NCK analog inputs (Page 37)".
MD10330 $MN_FASTIO_ANA_OUTPUT_WEIGHT[<n>] Weighting factor for the analog
NCK outputs
For further information, see
"NCK analog outputs
(Page 39)".
Assignment to NC functions
Several NC functions are dependent on the functionality of the NCK I/Os.
The assignment of the NCK I/Os used for these NC functions is performed function-
specifically via machine data, e.g. for the "Multiple feedrates in one block" function via the
machine data:
MD21220 $MC_MULTFEED_ASSIGN_FASTIN
A byte address should be specified in the machine data for digital inputs/outputs. The
assignment is always byte-by-byte.
Byte address Assignment for the digital NCK I/Os

0 None
1 1 to 4 (on-board I/O) and 5 to 8 (NCK output without hardware)
2 9 to 16 (external NCK I/Os)
128 Inputs 1 to 8 of comparator byte 1
129 Inputs 9 to 16 of comparator byte 2
Note
Multiple assignments
Multiple assignments of inputs are not monitored.
Multiple assignments of outputs are checked during run-up and indicated by an alarm.
Extended Functions
1.2 Access via PLC
1.2.3 NCK digital inputs/outputs
1.2.3.1 NCK digital inputs
Function
The workpiece-machining program sequence can be controlled by external signals via digital
NCK inputs.
The signal state of digital input <n> can be scanned directly in the part program using
system variable $A_IN [<n>].
The signal state at the hardware input can be changed from the PLC user program.
Applications
Digital NCK inputs are used, for example, for the following NC functions:
Delete distance-to-go with positioning axes
Fast program branching at the end of block
Programmed read-in disable
Several feedrates in one block
References:
Function Manual, Synchronized Actions
Signal flow
The following figure illustrates the signal flow for the digital NCK inputs.
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Extended Functions
1.2 Access via PLC
Read actual value

The signal state of the digital NCK inputs is sent to the PLC:
DB10, DBB60 or DBB186 ... (actual value for digital NCK inputs)
The actual value reflects the actual state of the signal at the hardware input. The influence of
the PLC is ignored for the "actual value".
Disable input
Digital NCK inputs can be disabled individually from the PLC user program:
DB10 DBB0 or DBB122 ... (block the digital NCK inputs)
In this case, they are set to a defined "0" inside the control.
Set input from PLC

The PLC can also set each digital input to a defined "1" signal:
DB10 DBB1 or DBB123 ... (setting of the digital NCK inputs from the PLC)
As soon as this interface signal is set to "1", the signal state at the hardware input or the
input disable is inactive.
Behavior during POWER ON / reset

After POWER ON and reset, the signal level at the respective input is passed on. If
necessary, the PLC user program can disable or set the individual inputs to a defined "1" as
described above.
1.2.3.2 NCK digital outputs
Function
Time-critical switching operations can be triggered very quickly via the digital NCK outputs,
bypassing the PLC cycle times for the relevant machining and program-controlled (e.g. with
the block change).
The signal state of digital output <n> can be set or read again directly in the part program
using system variable $A_OUT[<n>].
There are also several ways of changing this set signal state via the PLC.
Applications
Digital NCK outputs are used, for example, for the following NC functions:
Position switching signals (see Section "N3: Software cams, position switching cycles -
only 840D sl (Page 535)")
Output of comparator signals
Extended Functions
1.2 Access via PLC
Signal flow
The following figure illustrates the signal flow for the digital NCK outputs.
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Overwrite mask
Every output that can be set by the NC part program can be overwritten from the PLC using
the overwrite mask. The previous "NCK value" is lost.
The following sequence has to be carried out to overwrite the NCK value from the PLC:
1. The relevant PLC interface output has to be set to the required signal status.
DB10 DBB6 or DBB132 ... (setting value of the digital NCK outputs from the PLC)
2. The "setting value" becomes the new "NCK value" when the overwrite mask for the
relevant output is activated (edge change 0 1).
DB10 DBB5 or DBB131 ...
This value remains operative until a new NCK value is programmed (from the PLC or
from the part program).
Extended Functions
1.2 Access via PLC
Setting mask
A PLC setting for each output can determine whether the current "NCK value" (e.g. as
specified by the NC part program) or the "PLC value" specified via the setting mask should
be output at the hardware output.
The following sequence has to be carried out to define the "PLC value":
1. The relevant PLC interface output has to be set to the required signal status.
DB10 DBB6 or DBB132 ... (setting value of the digital NCK outputs from the PLC)
2. The setting mask must be set to "1" for the relevant output:
DB10 DBB7 or DBB133 ... (setting mask of the digital NCK outputs)
Unlike the overwrite mask, the NCK value is not lost when a value is set in the setting mask.
As soon as the PLC sets "0" in the corresponding setting mask, the NCK value becomes
active again.
Note
The same setting value is used at the PLC interface for the overwrite and setting masks.
Therefore, an identical output signal state is the result if the signal state is changed
simultaneously in the overwrite and setting masks.
Disable output
Digital NCK outputs can be disabled individually from the PLC user program:
DB10 DBB4 or DBB130 ... (block the digital NCK outputs)
In this case, the "0" signal is output at the hardware output.
Read setpoint
The current "NCK value" of the digital outputs can be read by the PLC user program:
DB10, DBB64 or DBB186 ... (setpoint for digital NCK outputs)
Please note that this setpoint ignores disabling and the PLC setting mask. Therefore, the
setpoint can differ from the actual signal state at the hardware output.
Behavior at program end / reset

At the end of the program or on reset, a specific default value can be assigned by the PLC
user program to every digital output in accordance with requirements, using the overwrite
mask, setting mask or disable signal.
Response to POWER ON
After POWER ON, the digital outputs are set to "0" in a defined manner. This can be
overwritten from the PLC user program according to the specific application using the
overwrite or setting mask.
Digital NCK outputs without hardware

If digital NCK outputs, as defined via MD10360, are written by the part program, but are not
available as hardware, no alarm is output. The NCK value can be read by the PLC (DB10
DBB64 or DBB186 ... ).
Extended Functions
1.2 Access via PLC
1.2.3.3 Connection and logic operations of fast digital NCK I/Os
Function
Fast NCK I/O inputs can be set by software as a function of fast-output signal states.
Overview:
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The NCK I/O fast input is set to the signal state of the assigned fast output.
OR operation
The NCK I/O fast input adopts the signal state as a result of the ORing of the output signal
with the assigned input signal.
AND operation
The NCK I/O fast input adopts the signal state as a result of the ANDing of the output signal
with the assigned input signal.
Special cases
If several output bits are assigned to the same input bit, then the one with the highest MD
index becomes effective.
If inputs or outputs are specified which do not exist or are not activated, then the
assignment is ignored without an alarm. Checking of the active bytes of the NCK I/Os is
performed via the entries in machine data:
MD10350 $MN_FASTIO_DIG_NUM_INPUTS
MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS
Extended Functions
1.2 Access via PLC
Defining assignments
The assignments are specified via machine data:
MD10361 $MN_FASTIO_DIG_SHORT_CIRCUIT[n]
n: can accept values 0 to 9, so up to 10 assignments can be specified.
Two hexadecimal characters are provided for specifying the byte and bit of an output and an
input.
Specifying 0, A and B in input bits 12 - 15 results in the following logic operations:
0 Connecting
A AND operation
B OR operation
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Connect:
MD10361 $MN_FASTIO_DIG_SHORT_CIRCUIT = '04010302H'
Output 4, byte 1, connect to
Input 3, byte 2
AND operation:
MD10361 $MN_FASTIO_DIG_SHORT_CIRCUIT = '0705A201H'
Output 7, byte 5 AND operation with
Input 2, byte 1
OR operation:
MD10361 $MN_FASTIO_DIG_SHORT_CIRCUIT = '0103B502H'
Output 1, byte 3 OR operation with
Input 5, byte 2
Extended Functions
1.2 Access via PLC
1.2.4 NCK analog I/Os
1.2.4.1 NCK analog inputs
Function
The value of the analog NCK input [<n>] can be accessed directly in the part program using
system variable $A_INA[<n>].
The analog value at the hardware input can be controlled from the PLC user program.
Applications
The analog NCK inputs are used particularly for grinding and laser machines, e.g. for the
"analog calipers" NC function.
Signal flow
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Extended Functions
1.2 Access via PLC
Read actual value

The analog values that are actually present at the hardware inputs are are sent to the PLC:
DB10 DBW194 ... 208 (actual value of the NCK analog input)
The possible influence of the PLC is ignored for the "actual value".
Disable input
Analog NCK inputs can be disabled individually from the PLC user program:
DB10 DBB146 (Disable analog NCK inputs)
In this case, they are set to a defined "0" inside the control.
Set input from PLC

The PLC can also specify a value for each analog NCK input:
DB10 DBB147 (analog value specification for NCK from the PLC)
As soon as this interface signal is set to "1", the setting value set by the PLC becomes active
for the corresponding analog input.
DB10 DBW148-162 (setpoint from the PLC for analog NCK input)
The analog value at the hardware input or the input disable is then inactive.
Weighting factor
The weighting factor can be used to adapt each individual NCK input to the various AD
converters (depending on the I/O module ) for reading in the part program:
MD10320 $MN_FASTIO_ANA_INPUT_WEIGHT[<n>]
In this machine data, it is necessary to enter the value x that is to be read in the part program
with the system variable $A_INA[<n>], if the corresponding analog input <n> is set to the
maximum value or if the value 32767 is set for this input via the PLC interface. The voltage
level at the analog input is then read with system variable $A_INA[<n>] as a numerical value
with the unit millivolts.
Note
Application for analog NCK inputs without hardware:
With a weighting factor of 32767, the digitized analog values for part program and PLC
access are identical. In this way, it is possible to use the associated input word for 1:1
communication between the part program and the PLC.
Extended Functions
1.2 Access via PLC
Binary analog-value display

See "Representation of the NCK analog input/output values (Page 43)".
Behavior during POWER ON / reset

After POWER ON and reset, the analog value at the respective input is passed on. If
necessary, the PLC user program can disable or set the individual inputs to a setpoint.
Analog NCK input without hardware

The following value is read in the case of part program access to analog NCK inputs that are
defined via MD10300, but are not available as hardware inputs:
The setpoint specified from the PLC (if the IS "Analog value input for NCK from the PLC"
is set to "1")
0 volts (if the IS "Analog value input for NCK from the PLC" is not set)
This makes it possible to use the functionality of the analog NCK inputs from the PLC user
program without I/O hardware.
1.2.4.2 NCK analog outputs
Function
Analog values to be output very quickly via the analog NCK outputs, bypassing the PLC
cycle times.
The value of the analog output <n> can be defined directly in the part program using system
variable $A_OUTA[<n>].
Before output to the hardware I/Os, the analog value set by the NCK can be changed by the
PLC.
Application
The analog NCK outputs are used in particular for grinding and laser machines.
Extended Functions
1.2 Access via PLC
Signal flow
The following figure illustrates the signal flow for the analog NCK outputs.
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Extended Functions
1.2 Access via PLC
Overwrite mask
Every NCK analog value set by the part program can be overwritten from the PLC using the
overwrite mask. The previous "NCK value" is lost.
The following sequence has to be carried out to overwrite the NCK value from the PLC:
1. The relevant PLC interface output <n> has to be set to the required analog value.
DB10 DBW170 (setpoint from the PLC for analog output <n> of the NCK)
2. The "setpoint from the PLC" becomes the new "NCK value" when the overwrite mask for
the relevant analog output is activated (edge change 0 1).
DB10 DBB166 (overwrite mask of analog NCK outputs)
This value remains operative until a new NCK value is programmed (from the PLC or from
the part program).
Setting mask
A PLC setting for each output can determine whether the current "NCK value" (e.g. as
specified by the NC part program) or the "PLC value" specified via the setting mask should
be output at the hardware analog output.
The following sequence has to be carried out to define the "PLC value":
1. The relevant PLC interface output has to be set to the required analog value.
DB10 DBW170 (setpoint from the PLC for analog output <n> of the NCK)
2. The setting mask must be set to "1" for the relevant analog output:
DB10 DBB167 (Setting screen form of analog NCK outputs)
Unlike the overwrite mask, the NCK value is not lost when a value is set in the setting mask.
As soon as the PLC sets "0" in the corresponding setting mask, the NCK value becomes
active again.
Note
The same setpoint is used at the PLC interface for the overwrite and setting masks.
Disable output
Analog NCK outputs can be disabled individually from the PLC user program:
DB10 DBB168 (disable analog NCK outputs)
In this case, the "0" signal is output at the hardware output.
In this case, 0 volt is output at the analog output.
Read setpoint
The current "NCK value" of the analog outputs can be read from the PLC user program:
DB10 DBW210 (setpoint of the analog output <n> of the NCK)
Please note that this setpoint ignores disabling and the PLC setting mask. Therefore, the
setpoint can differ from the actual analog value at the hardware output.
Extended Functions
1.2 Access via PLC
Weighting factor
The weighting factor can be used to adapt each individual NCK output to the various DA
converters (depending on the I/O module ) for programming in the part program:
MD10330 $MN_FASTIO_ANA_OUTPUT_WEIGHT[<n>]
In this machine data, it is necessary to enter the value x that is to cause the analog output
<n> to be set to the maximum value or the value 32767 to be set for this output in the PLC
interface, if $A_OUTA[n] = x is programmed. The value set with system variable
$A_OUTA[<n>] then generates the corresponding voltage value at the analog output in
millivolts.
Example:
Analog-value range is 10 V (maximum modulation);
MD10330 $MN_FASTIO_ANA_OUTPUT_WEIGHT[<n>] = 10000 (default value)
$A_OUTA[1] = 9500; 9.5 V is output at analog NCK output 1
$A_OUTA[3] = -4120; -4.12 V is output at analog NCK output 3
Note
Application for analog NCK outputs without hardware:
With a weighting factor of 32767, the digitized analog values for part program and PLC
access are identical. In this way, it is possible to use the associated output word for 1:1
communication between the part program and the PLC.
Binary analog-value display

See "Representation of the NCK analog input/output values (Page 43)".
Behavior at program end / reset

At the end of the program or on reset, a specific default value can be assigned by the PLC
user program to every analog output in accordance with requirements, using the overwrite
mask, setting mask or disable signal.
Response to POWER ON
After POWER ON, the analog outputs are set to "0" in a defined manner. This can be
overwritten from the PLC user program according to the specific application using the
overwrite or setting mask.
Analog NCK outputs without hardware

If analog NCK outputs, as defined via MD10310, are written by the part program, but are not
available as hardware, no alarm is output. The NCK value can be read by the PLC (DB10
DBB210 ).
Extended Functions
1.2 Access via PLC
1.2.4.3 Representation of the NCK analog input/output values

The digitized analog values are represented at the NC/PLC interface as fixed-point numbers
(16 bits including sign) in the two's complement.
Bit number 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Significanc SG 214 213 212 211 210 29 28 27 26 25 24 23 22 21 20
e
SG: Sign
Minimum value Maximum value

-32768D 32767D
8000H 7FFFH
Increment
For a resolution of 16 bits and a nominal range of 10 V, the increment is:
20 V / 216 = 20 V / 65536 0.305 mV
Resolutions < 16 bits

If the resolution of an analog module is less than 16 bits including sign, then the digitized
analog value is entered in the interface starting from bit 14. The unused least significant bit
positions are filled with "0".
14-bit resolution
For a resolution of 14 bits including sign and a nominal range of 10 V, the increment is:
20 V / 214 = 20 V / 16384 1.22 mV
Bit 0 ... 1 are always "0".
12-bit resolution
For a resolution of 12 bits including sign and a nominal range of 10 V, the increment is:
20 V / 212 = 20 V / 4096 4.88 mV
Bit 0 ... 3 are always "0".
Extended Functions
1.2 Access via PLC
Representation of the maximum value for different resolutions
Bit number 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Significance of the bits SG 214 213 212 211 210 29 28 27 26 25 24 23 22 21 20
16-bit resolution: 32767D = 7FFFH 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
14-bit resolution: 8191D = 1FFFH 0 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0
12-bit resolution: 2047D = 7FFH 0 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0
Note
The data (resolution, nominal range) of the analog input/output module used can be taken
from the documentation of the particular module.
Examples
Digital representation of analog values at a resolution of 14 bits including sign and a nominal
range of 10 V.
Example 1: Analog value = 9.5 V
Digitized analog value (decimal): 9.5 V / 20 V * 16384 = 7782

Digitized analog value 14-bit (binary): 01 1110 0110 0110

Digitized analog value 16-bit (hex): 7998H
Example 2: Analog value = -4.12 V
Digitized analog value (decimal): -4.12 V / 20 V * 16384 = -3375


Digitized analog value 16-bit (hex): CB44 H
Extended Functions
1.2 Access via PLC
1.2.5 Comparator inputs
Function
Two internal comparator input bytes, each with eight comparator inputs, are available in
addition to the digital and analog NCK inputs. The signal state of the comparator inputs is
generated on the basis of a comparison between the analog values present at the fast
analog inputs and the threshold values parameterized in setting data.
The $A_INCO[<n>] system variable allows the signal state (i.e. the result of the comparison)
of comparator input [<n>] to be scanned directly in the part program.
Applies for index <n>:
<n> = 1 ... 8 For comparator byte 1

<n> = 9 ... 16 For comparator byte 2
Terms
The terms comparator inputs (with index <n>; value range from <n>: 1 ... 8 or 9 ... 16) and
comparator input bits (with index ; value range from : 0 ... 7) are used in this
description.
They are related as follows:
For <n> = 1 ... 8: Comparator input <n> is equivalent to comparator input bit
 = <n> - 1.
For <n> = 9 ... 16: Comparator input <n> is equivalent to comparator input bit
 = <n> - 9.
Example: Comparator input 1 is equivalent to comparator input bit 0.
Assignment of the analog inputs

The following machine data is used to assign an analog input to input bit of comparator
byte 1:
MD10530 $MN_COMPAR_ASSIGN_ANA_INPUT_1[]
Example:
MD10530 $MN_COMPAR_ASSIGN_ANA_INPUT_1[0] = 1
Analog input 1 acts on input bits 0 and 1 of comparator byte 1.
Analog input 7 acts on input bit 7 of comparator byte 1.
The analog inputs for comparator byte 2 are assigned with the machine data:
MD10531 $MN_COMPAR_ASSIGN_ANA_INPUT_2[]
Extended Functions
1.2 Access via PLC
Comparator settings
The settings for the individual bits (0 to 7) of comparator byte 1 or 2 are parameterized via
the machine data:
MD10540 $MN_COMPAR_TYPE_1 (parameter assignment for comparator byte 1)
or
MD10541 $MN_COMPAR_TYPE_2 (parameter assignment for comparator byte 2)
The following settings are possible:
Comparison type mask (bits 0 7)
The type of comparison condition is defined for each comparator input bit:
Bit = 1: Associated comparator input bit is set to "1" if:

Analog value threshold value
Bit = 0: Associated comparator input bit is set to "0" if:
Analog value < threshold value
Output of the comparator input byte via digital NCK outputs (bits 16 23)
The comparator bits can also be output directly via the digital NCK outputs byte-by-byte.
This requires specification in this byte (bits 16 23) of the digital NCK output byte to be
used.
Byte = 0: No output via digital NCK outputs

Byte = 1: Output via digital on-board-NCK outputs 9 16
Byte = 2: Output via external digital NCK outputs 17 24
Inversion mask for output of the comparator input byte (bits 24 31)
For every comparator signal it is also possible to define whether the signal state to be
output at the digital NCK output is to be inverted or not.
Bit = 1: Associated comparator input bit is not inverted.

Bit = 0: Associated comparator input bit is inverted.
Threshold values
The threshold values used for comparisons on comparator byte 1 or 2 must be stored as
setting data. A separate threshold value must be entered for each comparator input bit 
(with = 0 7):
SD41600 $SN_COMPAR_THRESHOLD_1[]
or
SD41601 $SN_COMPAR_THRESHOLD_2[]
Extended Functions
1.2 Access via PLC
Comparator signals as digital NCK inputs

All NC functions that are processed as a function of digital NCK inputs can also be controlled
by the signal states of the comparators. The byte address for comparator byte 1 (HW byte
128) or 2 (HW byte 129) must be entered in the machine data associated with the NC
function ("Assignment of hardware byte used").
Example:
"Multiple feedrates in one block" NC function
Entry in channel-specific machine data:
MD21220 $MC_MULTFEED_ASSIGN_FASTIN = 129
This activates various feedrate values as a function of the status of comparator byte 2.
Functional sequence
The functional sequence for comparator input byte 1 is represented schematically in the
following figure.
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Extended Functions
1.2 Access via PLC
1.2.6 Direct PLC I/Os, addressable from the NC
1.2.6.1 Function
The fast data channel between the NCK and PLC I/Os is processed directly and therefore
quickly by the PLC operating system.
There is no provision for control of the PLC basic and user programs. It is not advisable for
the NCK and the PLC to attempt to access the same PLC I/Os simultaneously, as this can
result in faults.
Data exchange
For access purposes, the NC uses system variables associated with part programs and
synchronized actions.
Table 1- 2 For reading from PLC:
$A_PBB_IN[<n>] Read byte (8-bit)

$A_PBW_IN[<n>] Read word (16-bit)
$A_PBD_IN[<n>] Read double word (32-bit)
$A_PBR_IN[<n>] Read real (32-bit float)
<n> = Byte offset within the PLC input area
Reading from the part program causes a preprocessing stop.
Table 1- 3 For writing to PLC:
$A_PBB_OUT[<n>] ; Write byte (8-bit)

$A_PBW_OUT[<n>] ; Write word (16-bit)
$A_PBD_OUT[<n>] ; Write data word (32-bit)
$A_PBR_OUT[<n>] ; Write real (32-bit float)
<n> = Byte offset within the PLC output area
The output data can also be read from the part program and synchronized actions. Reading
from the part program causes an automatic preprocessing stop (to achieve synchronization
with the real-time context).
Ranges of values
Values within the following ranges can be stored in the system variables:
System variable Value range

$A_PBB_OUT[<n>]: (-128 ... +127) or (0 ... 255)
$A_PBW_OUT[<n>]: (-32768 ... +32767) or (0 ... 65535)
$A_PBD_OUT[<n>]: (-2147483648 ... +2147483647) or (0 ... 4294967295)
$A_PBR_OUT[<n>]: (-3.402823466E+38 ... +3.402823466E+38)
Extended Functions
1.2 Access via PLC
Transfer times
Data is output from NCK PLC (write) at the end of the interpolation cycle if at least one
data item was written.
Data is read in by transmitting a request at the end of the interpolation cycle.
The new data is available in the subsequent interpolation cycle at the earliest.
The time period within which a request is sent to the PLC, can be specified via the machine
data:
MD10398 $MN_PLCIO_IN_UPDATE_TIME
The entered time period is rounded up internally to the next highest multiple of an
interpolation cycle. If the value of this machine data is set to "0", the request will continue to
be sent to the PLC in every interpolation cycle.
Configuring
To activate the functionality, the following machine data (Power ON active) must be
configured on the NC:
MD10394 $MN_PLCIO_NUM_BYTES_IN
Number of PLC I/O input bytes that are read directly by the NC
MD10395 $MN_PLCIO_LOGIC_ADDRESS_IN
Logical start address of the PLC input I/O, starting at which the data is read
MD10396 $MN_PLCIO_NUM_BYTES_OUT
Number of PLC I/O output bytes that are written directly by the NC
MD10397 $MN_PLCIO_LOGIC_ADDRESS_OUT
Logical start address of the PLC output I/O, starting at which the data is written
MD10398 $MN_PLCIO_IN_UPDATE_TIME
Time period within which the data that can be read by means of $A_PBx_IN is updated
(see Section "Transfer times").
MD10399 $MN_PLCIO_TYPE_REPRESENTATION
Format display of system variables $A_PBx_OUT and $A_PBx_IN (see Section "Memory
organization").
Note
The logical PLC I/O addresses entered in the machine data and the number of bytes to be
transferred must be consistent with the PLC hardware configuration. In the configured areas,
there must not be any "address gaps" in the PLC I/O expanded configuration.
Extended Functions
1.2 Access via PLC
Memory organization
16 bytes (over all channels) are available for data exchange from and to the PLC
respectively. These areas have to be managed by the user (i.e. no overlapping of the
variables, not even across channel borders).
The display of the variables within these areas depends on the setting in the machine data:
MD10399 $MN_PLCIO_TYPE_REPRESENTATION
Value Meaning
0 (default setting)
System variables are displayed in little-endian format
(i.e. least significant byte at least significant address)
1 (PLC standard format, recommended)
System variables are displayed in big-endian format
(i.e. most significant byte at least significant address)
Since big-endian format is generally the most common display type on the PLC (i.e. it also
applies to the PLC I/Os), it should normally be used.
Note
The assignment of the input and output areas for direct PLC I/Os must satisfy the
following conditions:
$A_PBB_IN[<j>] ; j < ([MD10394 $MN_PLCIO_NUM_BYTES_IN])

$A_PBW_IN[<j>] ; j < ([MD10394 $MN_PLCIO_NUM_BYTES_IN] - 1)
$A_PBD_IN[<j>] ; j < ([MD10394 $MN_PLCIO_NUM_BYTES_IN] - 3)
$A_PBR_IN[<j>] ; j < ([MD10394 $MN_PLCIO_NUM_BYTES_IN] - 3)
$A_PBB_OUT[<k>] ; k < ([MD10396 $MN_PLCIO_NUM_BYTES_OUT])

$A_PBW_OUT[<k>] ; k < ([MD10396 $MN_PLCIO_NUM_BYTES_OUT] - 1)
$A_PBD_OUT[<k>] ; k < ([MD10396 $MN_PLCIO_NUM_BYTES_OUT] - 3)
$A_PBR_OUT[<k>] ; k < ([MD10396 $MN_PLCIO_NUM_BYTES_OUT] - 3)
The maximum number of bytes available for data exchange must not be exceeded.
Extended Functions
1.2 Access via PLC
1.2.6.2 Supplementary conditions
Configuration
If the PLC I/Os are to be written/read via the fast data channel, they must always be
configured as a cohesive block (i.e. no address gaps within this block).
It must be possible for the number of bytes that have to be transferred to be mapped
without gaps on the PLC I/Os.
Time response
The time when the data is read in from the PLC I/Os is not synchronized with the time when
the data is made available to the part program via system variables!
Data transfer (NCK PLC)

The data buffer is always output complete to the PLC I/Os, even if only one system
variable was assigned within the data buffer.
If values are assigned to several system variables simultaneously (e.g. for initializing the
PLC I/Os), there is no guarantee that they will be transferred in the same interpolation
cycle.
Extended Functions
1.2 Access via PLC
1.2.6.3 Examples
Writing to PLC-I/Os
The following assumptions are made in this example:
Data is to be output directly to the following PLC I/Os:
- log. addr. 521: 8-bit digital output module

- log. addr. 522: 16-bit digital output module
$A_PBx_OUT is used to output the data from synchronized actions.
Parameter assignment
The machine data should be set as follows:
MD10397 $MN_PLCIO_LOGIC_ADRESS_OUT= 521 ; Data is output from log. addr.

521 onwards
MD10396 $MN_PLCIO_NUM_BYTES_OUT= 3 ; A total of three bytes have to
be output
MD10399 $MN_PLCIO_TYPE_REPRESENTATION = 1 ; Data is displayed in big-endian
format
Run-up of NCK and PLC
Once the NCK and PLC have run up, there is no cyclic data transfer to the PLC I/Os (for
write access).
Programming
Loading and starting of the part program with the following content:
Program code Comment

...
ID=1 WHENEVER TRUE DO $A_PBB_OUT[0]=123 ; Cyclic output (per interpolation cycle)
...
ID=2 WHEN $AA_IW[x] >= 5 DO $A_PBW_OUT[1]='Habcd' ; Output of a HEX value
...
Extended Functions
1.2 Access via PLC
Reading from PLC-I/Os

The following assumptions are made in this example:
PLC I/Os:
- log. addr. 420: 16-bit analog input module

- log. addr. 422: 32-bit digital input module
- log. addr. 426: 32-bit DP slave input
- log. addr. 430: 8-bit digital input module
$A_PBx_IN is used to read in data from a part program into R parameters.
In order to avoid slowing down the PLC user program unnecessarily (OB1), an update
time (for read access) was configured via MD10398 $MN_PLCIO_IN_UPDATE_TIME so
that an update is only performed in every third interpolation cycle.
The machine data should be set as follows:
MD10395 $MN_PLCIO_LOGIC_ADRESS_IN = 420 ; Data is read in from log.

addr. 420 onwards
MD10394 $MN_PLCIO_NUM_BYTES_IN = 11 ; A total of 11 bytes have to be
read in
MD10398 $MN_PLCIO_IN_UPDATE_TIME = 0.03 ; Update time period = 30 ms
(interpolation cycle = 12 ms)
MD10399 $MN_PLCIO_TYPE_REPRESENTATION = 1 ; Data is displayed in big-
endian format
Run-up of NCK and PLC:
The update (for read access) is now performed in every third interpolation cycle after the
NCK and PLC have run up.
Programming
Loading and starting of the part program with the following content:

...
R1=$A_PBW_IN[0] ; Read in 16-bit integer
R2=$A_PBD_IN[2] ; Read in 32-bit integer
R3=$A_PBR_IN[6] ; Read in 32-bit float
R4=$A_PBB_IN[10] ; Read in 8-bit integer
...
Extended Functions
1.3 Access via PROFIBUS
1.3.1 Brief description
Function
The function "I/O access via PROFIBUS" implements a direct data exchange between the
NCK and the PROFIBUS I/O.
Availability
The function is available for isochronous and non-isochronous configured PROFIBUS I/O.
Hardware requirements
The required PROFIBUS I/O must be available and ready to use.
A correct S7 HW configuration (PLC-side) must be carried out with the required
PROFIBUS I/O, and loaded in the PLC.
An I/O range must be present on the same PROFIBUS slave.
I/O range
If the individual user data slots of a PROFIBUS slave are configured in the S7 HW
configuration (PLC) in such a way that they form a contiguous PROFIBUS I/O section in
series, with logical start addresses in ascending order, then this section is referred to as I/O
range in the following.
An I/O range is characterized by:
A logical start address (this corresponds to the logical start address of the first user data
slot of this I/O range).
A configured length (this corresponds to the length in bytes of the connected PROFIBUS
I/O to be accessed).
The logical start addresses of the I/O range must be available in the NCK, so that it can
read/write the corresponding data of the PROFIBUS I/O via an NCK-internal PROFIBUS
communication interface. The configured I/O range is registered via machine data (see
"Configuration of the I/O ranges (Page 56)". The communication with the PROFIBUS I/O is
thus possible only I/O range-oriented.
Extended Functions
Data exchange
The data exchange with the PROFIBUS I/O is performed via an NCK-internal PROFIBUS-
communication interface. The following options of data exchange with the PROFIBUS I/O
are available to the NCK user:
Reading/writing of NCK system variables ($A_DPx_IN[n,m] or $A_DPx_OUT[n,m]) via
part programs / synchronized actions in the IPO cycle (data consistency). The
PROFIBUS I/O data to be written is output at the PROFIBUS I/O only after the
corresponding IPO cycle.
See "Communication via part programs/synchronous actions (Page 58)".
Read in / output of the data blocks via the compile-cycle interface (data consistency for
servo cycle).
See "Communication via compile cycles (Page 61)".
Parallel data access

A parallel read access through compile cycles and part programs / synchronized actions on
data of the same I/O range is possible, as long as the corresponding I/O range has been
configured for this. One must ensure that the read accesses have access to the different
mappings of the PROFIBUS I/O data. The data consistency within these mappings is
ensured. However, the data equality between these mappings cannot be ensured during an
IPO cycle.
A parallel write access through compile cycles and part programs / synchronized actions on
data of the same I/O range is not possible. While configuring the NCK it must be determined,
whether a specific I/O range of the PROFIBUS I/O is allocated to the system variables or to
the compile cycles.
Activation
The function is activated during the NCK run-up.
Extended Functions
1.3.2 Configuration of the I/O ranges

The configuration of the I/O range is performed via the machine data. The parameters once
set can no longer be changed during the normal operation of the NCK.
16 I/O ranges in the read direction and 16 I/O ranges in the write direction are provided. NCK
restricts the maximum size of the I/O ranges to 128 bytes each.
Once an I/O range is activated, its availability is checked each time an IPO cycle starts. For
this, the sign of life of a user data slot within an I/O range is evaluated. If the sign of life is not
set at the start of an IPO cycle, an alarm (9050 or 9052) is issued. This alarm does not stop
the processing of the part program, but instead is only displayed and remains as such till the
affected I/O range gets a valid sign of life again.
Logical start address

To make specific I/O ranges available again, their logical start addresses must be conveyed
to the NCK. The following machine data must be set:
MD10500 $MN_DPIO_LOGIC_ADDRESS_IN[<n>]
MD10510 $MN_DPIO_LOGIC_ADDRESS_OUT[<n>]
<n> = index for the I/O range
Length of an I/O range

In order that the NCK can check, whether an I/O range has been configured completely, the
expected length (bytes) of the corresponding I/O range must be entered. The following
machine data must be set:
MD10501 $MN_DPIO_RANGE_LENGTH_IN[<n>]
MD10511 $MN_DPIO_RANGE_LENGTH_OUT[<n>]
If the length "0" is entered, only the user data slot found under the corresponding logical start
address is configured as I/O range. In such a case, the length of the I/O range is then
compared to the length of the user data slot found.
Extended Functions
Further attributes
Further attributes can be allocated to each I/O range with the following machine data:
MD10502 $MN_DPIO_RANGE_ATTRIBUTE_IN[<n>]
Bit Value Meaning

0 Format display of system variables $A_DPx_IN[<n>,<m>]
0 Little-endian format
1 Big-endian format
1 Reserved
2 Reading of input data
0 Reading possible via system variables and CC-binding
1 Reading possible only for CC-binding
3 Output of slot sign-of-life alarms
0 Slot sign-of-life alarms are issued
1 Slot sign-of-life alarms are suppressed
MD10512 $MN_DPIO_RANGE_ATTRIBUTE_OUT[<n>]
Bit Value Meaning

0 Format display of system variables $A_DPx_OUT[<n>,<m>]
0 Little-endian format
1 Big-endian format
1 Writing of output data
0 Writing only via system variable
1 Writing only via CC-binding
2 Reserved
3 Output of slot sign-of-life alarms
0 Slot sign-of-life alarms are issued
1 Slot sign-of-life alarms are suppressed
Note
The configuration of the I/O ranges via the corresponding machine data need not be done
persistently. That is, the assignment of the I/O ranges to the corresponding machine
data-indices can be selected in any way.
If the registration of one/several I/O range(s) does not run successfully during the NCK
run-up phase, the registration is aborted with an alarm (4700 or 4702).
Extended Functions
1.3.3 Data exchange

The following requirements must be satisfied for direct data exchange with the PROFIBUS
I/O via the NCK-internal PROFIBUS communication interface:
Correct configuration of the corresponding I/O ranges.
PLC must actually be able to provide the required I/O ranges (user data slots).
The configured I/O ranges are released for use only when the PROFIBUS communication
interface is able to do a data exchange with the corresponding PROFIBUS I/O for the first
time.
1.3.3.1 Communication via part programs/synchronous actions
General
The NCK global system variables enable access to the PROFIBUS I/O, whether read or
write, from the part programs / synchronized actions:
$A_DPx_IN [<n>,<m>]
$A_DPx_OUT [<n>,<m>]
The following must be observed:
When reading from or writing to these variables from a part program, a preprocessing
stop is triggered.
To ensure data consistency during programming from the part program and the
synchronized actions, the PROFIBUS I/O data is accessed which is kept consistent for
the respective IPO cycle.
If the same PROFIBUS I/O data is to be write-accessed several times within an IPO cycle
(e.g. synchronized actions, access from different channels, etc.), then the data of the last
write access is valid.
The PROFIBUS I/O data to be written is output at the PROFIBUS I/O only after the
corresponding IPO cycle.
Extended Functions
Access I/O range data

The following system variables are available for accessing the I/O range data:
Table 1- 4 NCK PROFIBUS I/O
System variable Value Meaning

$A_DPB_OUT[<n>,<m>] 8-bit unsigned Writing a data byte (8-bit) to PROFIBUS I/O
$A_DPW_OUT[<n>,<m>] 16-bit unsigned Writing a data word (16-bit) to PROFIBUS I/O
$A_DPSB_OUT[<n>,<m>] 8-bit signed Writing a data byte (8-bit) to PROFIBUS I/O
$A_DPSW_OUT[<n>,<m>] 16-bit signed Writing a data word (16-bit) to PROFIBUS I/O
$A_DPSD_OUT[<n>,<m>] 32-bit signed Writing a data double word (32-bit) to PROFIBUS I/O
$A_DPR_OUT[<n>,<m>] 32-bit REAL Writing output data (32-bit REAL) to PROFIBUS I/O
<n> = index for the output data range; <m> = byte index for the data
Table 1- 5 PROFIBUS I/O NCK

$A_DPB_IN[<n>,<m>] 8-bit unsigned Reading a data byte (8-bit) from PROFIBUS I/O
$A_DPW_IN[<n>,<m>] 16-bit unsigned Reading a data word (16-bit) from PROFIBUS I/O
$A_DPSB_IN[<n>,<m>] 8-bit signed Reading a data byte (8-bit) from PROFIBUS I/O
$A_DPSW_IN[<n>,<m>] 16-bit signed Reading a data word (16-bit) from PROFIBUS I/O
$A_DPSD_IN[<n>,<m>] 32-bit signed Reading a data double word (32-bit) from PROFIBUS I/O
$A_DPR_IN[<n>,<m>] 32-bit REAL Reading of output data (32-bit REAL) from PROFIBUS I/O
<n> = index for the input data range; <m> = byte index for the data
Check configuration of the I/O ranges

The configuration of the I/O ranges can be checked via the following system variables. Each
bit of these bit arrays corresponds to an I/O range. It is set when the I/O range is configured
for access via the part programs / synchronized actions.

$A_DP_IN_CONF 32-bit bit array Reading all configured input data ranges of the PROFIBUS I/O
$A_DP_OUT_CONF 32-bit bit array Reading all configured output data ranges of the PROFIBUS I/O
Extended Functions
Check availability of the I/O ranges

The availability of the I/O ranges can be checked via the following system variables. Each bit
of these bit arrays corresponds to an I/O range. It is set, when the I/O-range is ready for
access via the part programs/synchronous actions.

$A_DP_IN_VALID 32-bit bit array Reading all valid input data ranges of the PROFIBUS I/O
$A_DP_OUT_VALID 32-bit bit array Reading all valid output data ranges of the PROFIBUS I/O
Query state of an I/O range

The exact status of an I/O range can be queried with the help of the following system
variables.

$A_DP_IN_STATE[<n>] 0: Data range was not configured Reading the state of the input
<n> = index for the input 1: Data range could not be activated data range
data range 2: Data range is available
$A_DP_OUT_STATE[<n>] 3: Data range is currently not available Reading the state of the output
<n> = index for the output data range
data range
Query length of an I/O range

The configured length of an I/O range can be queried using the following system variables.
System variable Meaning

$A_DP_IN_LENGTH[<n>] Reading the length of the input data range
<n> = index for the input data range
$A_DP_OUT_LENGTH[<n>] Reading the length of the output data range
<n> = index for the output data range
Note
Via <n> (RangeIndex) the corresponding NCK-configured I/O range is selected. If the
required I/O range is not configured, it is indicated by issuing an alarm (17020).
The <m> (RangeOffset) points to the place (byte-offset) within the I/O range, from which
the data access is to be started. Data types can be read/written at any byte offset within
the I/O range. Read/write accesses which exceed the configured limits of the respective
I/O range are rejected with the generation of an alarm (17030).
Via the machine data MD10502 $MN_DPIO_RANGE_ATTRIBUTE_IN or MD10512
$MN_DPIO_RANGE_ATTRIBUTE_OUT (see "Configuration of the I/O ranges
(Page 56)"), the display format (little-/big-endian) for $A_DPx_IN[n,m] or
$A_DPx_OUT[n,m] system variables can be defined for the read/write direction as well as
for each individual I/O range.
Extended Functions
1.3.3.2 Communication via compile cycles
General
CC-bindings are available for importing/exporting data blocks via the compile cycle
interfaces. The access to the data of the I/O range takes place at the servo task level. The
data is updated in each servo cycle. Data consistency is thus given for each respective servo
cycle.
To have write access to the data of the I/O range via the CC-bindings, the relevant I/O
ranges must be activated during the NCK configuration for the programming via compile
cycles:
MD10512 $MN_DPIO_RANGE_ATTRIBUTE_OUT[<n>], bit 1 = 1
A simultaneous programming of these I/O ranges via part programs / synchronized actions is
prevented by issuing an alarm (17020).
It must be noted that the data is displayed in general in the PLC in the big-endian format.
Naturally, this also applies to the PROFIBUS I/O. Since the bindings support only byte-
oriented access to data ranges (byte offset, number of bytes to be transferred) within an I/O
range, you must pay attention to the correct display of the data types (16-bit, 32-bit, etc.).
CC-Bindings
The following CC-bindings are available:
CCDataOpi: getDpIoRangeConfiguration()
CCDataOpi: getDpIoRangeValid()
CCDataOpi: getDpIoRangeInInformation()
CCDataOpi: getDpIoRangeOutInformation()
CCDataOpi: getDpIoRangeInState()
CCDataOpi: getDpIoRangeOutState()
CCDataOpi: getDataFromDpIoRangeIn()
CCDataOpi: putDataToDpIoRangeOut()
Extended Functions
Note
The bindings
CCDataOpi: getDataFromDpIoRangeIn() or
CCDataOpi: putDataToDpIoRangeOut()
monitor during the read/write accesses the adherence to the limits of the respective I/O
range configured at the NCK and PLC side. Access to data / data ranges which do not lie
completely within the configured I/O range limits is rejected by returning the enumerator
CCDATASTATUS_RANGE_LENGTH_LIMIT.
If an attempt is made to access an I/O range which is not configured (or not configured
for the compile cycle), it is notified by means of the return enumerator
CCDATASTATUS_RANGE_NOT_AVAILABLE.
NOTICE
Possible system slowdown
The compile cycle programmer is responsible for the correct use of the CC-bindings! It
must be noted that the additional performance requirement needed for providing the
data of the configured I/O ranges at the servo task level, does not lead to a servo level
computing time overflow.
See the OEM documents for more information about the use of these bindings.
1.3.4 Supplementary conditions
Hardware
Only the PROFIBUS-slaves at the first real PROFIBUS line of the PLC (plug with the
identification DP1) are supported.
Software
A simultaneous writing of the PROFIBUS I/O from a PLC-application program is not
permitted and cannot be prevented technically.
I/O ranges for the write access (MD10510 $MN_DPIO_LOCIG_ADDRESS_OUT[]) to the
PROFIBUS I/O may not lie in the I/O mapping range of the PLC (e.g. PLC 317,
addresses from 0 - 255), since this range is used by the PLC operating system.
Extended Functions
1.3.5 Examples
1.3.5.1 PROFIBUS-I/O in write direction
Requirement
The S7-HW-configuration is already done.
Configuration for programming via part program/synchronous actions

RangeIndex = 5 (NCK-internal configuration)
as per S7-HW-configuration:
log. start address = 334
Slot length = 8 byte
To be displayed in Little-Endian format
This results in the following configuration of the machine data:
MD10510 $MN_DPIO_LOGIC_ADDRESS_OUT[5] = 334 (log. start address I/O-range)
MD10511 $MN_DPIO_RANGE_LENGTH_OUT[5] = 8 (length of the I/O-range)
MD10512 $MN_DPIO_RANGE_ATTRIBUTE_OUT[5]
Bit0 = 0 (Little-Endian-Format)
Bit1 = 0 (writing only via system variable)
Bit3 = 0 (Slot-lifespan-alarms issued)
Configuration for programming via CompileCycles

MD10511 $MN_DPIO_RANGE_LENGTH_OUT[6] = 0
(a single useful-data slot is to be used)
Bit0 = 0 (Little-Endian-Format)
Bit1 = 1 (writing only via CC-binding)
Bit3 = 1 (Slot-lifespan-alarms suppressed)
Extended Functions
Programming

$A_DPB_OUT[5,6]=128 ; Write (8 bit) to RangeIndex=5, RangeOffset=6
$A_DPW_OUT[5,5]='B0110' ; Write (16 bit) to RangeIndex=5, RangeOffset=5
; Little Endian format
; Notice: RangeData of byte 6 are overwritten
$A_DPSD_OUT[5,3]=8FHex ; Write (32 bit) to RangeIndex=5, RangeOffset=3
; Notice: RangeData of byte 5.6 are overwritten
$AC_MARKER[0]=5
$AC_MARKER[1]=3
$A_DPSD_OUT[$AC_MARKER[0],$AC_MARKER[1]]=8FHex
; Write (32 bit) to RangeIndex=5, RangeOffset=3
; indirect programming
R1=$A_DPB_OUT[5,6] ; Read (8 bit) to RangeIndex=5, RangeOffset=6
; Result: 0xFF
ID=1 WHENEVER TRUE DO $A_DPB_OUT[5,0]=123
; Cyclic output (per IPO cycle)
$A_DPB_OUT[5.255]=128 ; Alarm 17030 because the RangeOffset is invalid.
$A_DPB_OUT[6.10]=128 ; Alarm 17020 because this range of the part program
; cannot be written.
$A_DPB_OUT[7.10]=128 ; Alarm 17020 because this range is not defined.
$A_DPB_OUT[16.6]=128 ; Alarm 17020 because RangeIndex >= max. available
; number of ranges.
Extended Functions
1.3.5.2 PROFIBUS-I/O in read direction
Requirement

To be displayed in Big-Endian format
MD10500 $MN_DPIO_LOGIC_ADDRESS_IN[0] = 456 (log. start address I/O-range)
MD10501 $MN_DPIO_RANGE_LENGTH_IN[0] = 32 (length of the I/O-range)
MD10502 $MN_DPIO_RANGE_ATTRIBUTE_IN[0]
Bit0 = 1 (Big-Endian-Format)
Bit2 = 0 (read possible via system variable and CC-binding)
Configuration for programming via CompileCycles

MD10500 $MN_DPIO_LOGIC_ADDRESS_IN[1] = 312 (log. start address I/O-range)
MD10501 $MN_DPIO_RANGE_LENGTH_IN[1] = 32 (length of the I/O-range)
MD10502 $MN_DPIO_RANGE_ATTRIBUTE_IN[1]
Bit2 = 1 (read possible only via CC-binding)
Bit3 = 1 (Slot-lifespan-alarms suppressed)
Extended Functions
Programming

$AC_MARKER[0]=$A_DPW_IN[0,0] ; Read (16 bit) to RangeIndex=0, RangeOffset=0
; Big Endian format
$AC_MARKER[1]=$A_DPSD_IN[0,1] ; Read (32 bit) to RangeIndex=0, RangeOffset=1
; Big Endian format
$AC_MARKER[1]=$A_DPSD_IN[0.8] ; Read (32 bit) to RangeIndex=0, RangeOffset=8
; Big Endian format
$AC_MARKER[2]=0
$AC_MARKER[3]=8
$AC_MARKER[1]=$A_DPSD_IN[$AC_MARKER[2],$AC_MARKER[3]]
; Read (32 bit) to RangeIndex=0, RangeOffset=8
; Big Endian format
; indirect programming
ID=2 WHEN $A_DPB_IN[0,11]>=5 DO $AC_MARKER[2]=ABCDHex
; Cyclic fetching (per IPO cycle)
R1=$A_DPB_IN[0,255] ; Alarm 17030 because the RangeOffset is invalid.
R1=$A_DPB_IN[2.6] ; Alarm 17020 because this range is not defined.
R1=$A_DPB_IN[1.10] ; Alarm 17020 because this range of the part
program cannot be written.
R1=$A_DPB_IN[16.6] ; Alarm 17020 because RangeIndex >= max. available
; number of ranges.
1.3.5.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write direction"
Requirement

To be displayed in Big-Endian format
Extended Functions

MD10511 $MN_DPIO_RANGE_LENGTH_OUT[5] = 0
(a single useful-data slot is to be used)
Bit1 = 0 (writing only via system variable)
Programming
before an access query the status of RangeIndex = 5

N3 check: ; Jump marker
N5 IF $A_DP_OUT_STATE[5]==2 GOTOF write ; if data range valid
; => jump to N15
N10 GOTOB check ; jump back to check
N15 write: ; Jump marker
N20 $A_DPB_OUT[5,6]=128 ; Writing the data byte
Query, whether all configured ranges/slots are valid

N5 IF $A_DP_OUT_CONF==$A_DP_OUT_VALID GOTOF ; if data range valid
write ; => jump to N15
N10 SETAL(61000) ;Set alarm no. 61000
Query, whether the configured RangeIndex = 5 is valid

N5 IF $A_DP_OUT_VALID B_AND B100000 GOTOF ; if data range valid
write ; => jump to N15
N10 SETAL(61000) ;Set alarm no. 61000
Querying the length of the configured, valid I/O-range with RangeIndex = 5

N100 R1=$A_DP_OUT_LENGTH[5] ; Length of the I/O-range (slot) in bytes
;Result: R1 = 32
Extended Functions
1.4 Data lists
1.4 Data lists
1.4.1 Machine data
1.4.1.1 General machine data
Number Identifier: $MN_ Description

10300 FASTIO_ANA_NUM_INPUTS Number of active analog NCK inputs
10310 FASTIO_ANA_NUM_OUTPUTS Number of active analog NCK outputs
10320 FASTIO_ANA_INPUT_WEIGHT Weighting factor for analog NCK inputs
10330 FASTIO_ANA_OUTPUT_WEIGHT Weighting factor for analog NCK outputs
10350 FASTIO_DIG_NUM_INPUTS Number of active digital NCK input bytes
10360 FASTIO_DIG_NUM_OUTPUTS Number of active digital NCK output bytes
10362 HW_ASSIGN_ANA_FASTIN Hardware assignment of external analog NCK inputs
10364 HW_ASSIGN_ANA_FASTOUT Hardware assignment of external analog NCK outputs
10366 HW_ASSIGN_DIG_FASTIN Hardware assignment of external digital NCK inputs
10368 HW_ASSIGN_DIG_FASTOUT Hardware assignment of external digital NCK outputs
10394 PLCIO_NUM_BYTES_IN Number of directly readable input bytes of the PLC I/Os
10395 PLCIO_LOGIC_ADDRESS_IN Start address of the directly readable input bytes of the PLC I/Os
10396 PLCIO_NUM_BYTES_OUT Number of directly writeable output bytes of the PLC I/Os
10397 PLCIO_LOGIC_ADDRESS_OUT Start address of the directly writeable output bytes of the PLC
I/Os
10398 PLCIO_IN_UPDATE_TIME Update time for PLC I/O input cycle
10399 PLCIO_TYPE_REPRESENTATION Little-/big-endian representation for PLC I/O
10500 DPIO_LOGIC_ADDRESS_IN Logical slot address of the PROFIBUS I/O
10501 DPIO_RANGE_LENGTH_IN Length of the PROFIBUS I/O range
10502 DPIO_RANGE_ATTRIBUTE_IN Attributes of the PROFIBUS I/O
10510 DPIO_LOGIC_ADDRESS_OUT Logical slot address of the PROFIBUS I/O
10511 DPIO_RANGE_LENGTH_OUT Length of the PROFIBUS I/O range
10512 DPIO_RANGE_ATTRIBUTE_OUT Attributes of the PROFIBUS I/O
10530 COMPAR_ASSIGN_ANA_INPUT_1 Hardware assignment of NCK analog inputs for comparator byte
1
10531 COMPAR_ASSIGN_ANA_INPUT_2 Hardware assignment of NCK analog inputs for comparator byte
2
10540 COMPAR_TYPE_1 Parameterization for comparator byte 1
10541 COMPAR_TYPE_2 Parameterization for comparator byte 2
Extended Functions
1.4 Data lists
1.4.1.2 Channelspecific machine data
Number Identifier: $MC_ Description

21220 MULTFEED_ASSIGN_FASTIN Assignment of input bytes of NCK I/Os for "multiple
feedrates in one block"
1.4.2 Setting data
1.4.2.1 General setting data
Number Identifier: $SN_ Description

41600 COMPAR_THRESHOLD_1 Threshold values for comparator byte 1
41601 COMPAR_THRESHOLD_2 Threshold values for comparator byte 2
1.4.3 Signals
1.4.3.1 Signals to NC
Signal name SINUMERIK 840D sl SINUMERIK 828D

Disable digital NCK inputs DB10.DBB0/122/124/126/128 DB2800.DBB0/1000
Setting on PLC of digital NCK inputs DB10.DBB1/123/125/127/129 DB2800.DBB1/1001
Disable digital NCK outputs DB10.DBB4/130/134/138/142 DB2800.DBB4/1008
Overwrite mask for digital NCK outputs DB10.DBB5/131/135/139/143 DB2800.DBB5/1009
Setting value from PLC for the digital NCK outputs DB10.DBB6/132/136/140/144 DB2800.DBB6/1010
Setting mask for digital NCK outputs DB10.DBB7/133/137/141/145 DB2800.DBB7/1011
Disable analog NCK inputs DB10.DBB146 -
Setting mask for analog NCK inputs DB10.DBB147 -
Setting value from PLC for the analog NCK inputs DB10.DBB148-163 -
Overwrite mask for analog NCK outputs DB10.DBB166 -
Setting mask for analog NCK outputs DB10.DBB167 -
Disable analog NCK outputs DB10.DBB168 -
Setting value from PLC for the analog NCK outputs DB10.DBB170-185 -
Extended Functions
1.4 Data lists
1.4.3.2 Signals from NC

Actual value for digital NCK inputs DB10.DBB60/186-189 DB2900.DBB0/1000
Setpoint for digital NCK outputs DB10.DBB64/190-193 DB2900.DBB4/1004
Actual value for analog NCK inputs DB10.DBB194-209 -
Setpoint for analog NCK outputs DB10.DBB210-225 -
Extended Functions
B3: Distributed systems - 840D sl only 2
2.1 Brief description
2.1.1 Several operator panels on several NCUs (T:M:N)

Under certain circumstances, a single operator control and monitoring station may not be
sufficient for complex plants and machines. Therefore, several operator control and
monitoring stations in a SINUMERIK system network (Ethernet) can be connected to several
numerical controls (NCU) via a PCU in such a way that they enable flexible and distributed
operation and monitoring of the entire system.
The following figure provides an overview of the components that currently can be connected
in a system network to form an operator control and monitoring system T:1:N. Meanings:
T: Thin Client Unit (TCU) or HT8 handheld unit (connected to the PCU)
1 (M): Man Machine Control (MMC), PCU 50.x with SINUMERIK Operate
N: Numeric Control Unit (NCU), NCU 7x0.3 PN
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Extended Functions
B3: Distributed systems - 840D sl only
Quantity structure
The following quantity structure must be observed for an operator control and monitoring
system T:1:N:
T: Thin Client Unit (TCU) or HT8 handheld unit

The graphic information of the PCU 50.x user interface is transferred via the TCU to the
operator panel front (OP) and displayed there. TCU and operator panel front together form
an operator station.
Maximum number
In principle, any number of operator stations, only limited by the amount of available
address space, can be operated in the system network.
Online
A maximum of four operator stations per PCU can be online simultaneously.
Operating focus
At any one time, only one of the operator stations on the PCU that are online, can have
the operating focus. Entries with regard to the user interface can only be made via this
operator station. The user interfaces on the other online operator stations are darkened to
indicate that they do not have operating focus. Only a message is displayed on operator
stations that are not online.
The operating focus can be switched between the online operator stations.
HT8 handheld unit
A HT8 handheld unit combines a TCU, an operator panel front and a machine control
panel in a single device.
M: PCU 50.x with SINUMERIK Operate

Several operator stations and several NCU 7x0.3 PN can be connected to a PCU 50.x with
SINUMERIK Operate user interface. The data of the channels of different NCUs can be
displayed on the operator stations through suitable configuring of the channel menu.
Note
Currently, only one PCU per T:1:N network can be configured M = 1
Extended Functions
N: SINUMERIK 840D sl, NCU 7x0.3 PN

Internal SINUMERIK Operate user interface
Because of the existing external SINUMERIK Operate user interface on PCU 50.x in the
system network, the NCU-integrated internal SINUMERIK Operate user interface must be
switched off. The internal SINUMERIK Operate user interface must not be switched off
only when it is used with a limited range of functions, exclusively within the scope of tool
management. Detailed information on this can be found in the Commissioning Manual
"Operator Components and Networking (IM5)", Section "Network configuration" >
"Application example"
Machine control panel (MCP)
For a flexible switchover of the machine control panels, only one MCP can be connected
to one NCU. The switchover of the MCPs is user-specifically via the PLC user program
(function block FB 9).
Installation and connection
References
TCU, MCP, PCU:
SINUMERIK 840D sl Operator Components and Networking Manual
NCU:
SINUMERIK 840D sl NCU 7x0.3 PN Manual
Machine control panel (MCP)
FB 9: MtoN Control Unit Switchover
Switch SCALANCE:
Communication with SIMATIC System Manual
Configuration, commissioning and parameter assignment
References
Structure of the system network and commissioning of a TCU:
Operator Components and Networking Commissioning Manual (IM5)
Configuration of the channel menu
SINUMERIK Operate Commissioning Manual (IM9), Section "Channel menu"
Programming
References
MCP:
Basic Functions Function Manual, Section "P3 Basic PLC program for SINUMERIK 840D
sl" > "Block descriptions" > "FB 9: MtoN control unit switchover"
Extended Functions
2.1.2 NCU link
2.1.2.1 Link communication

The NCU-link communication cycle allows an interpolation-synchronous cross-NCU data
exchange for the following applications:
Cross-NCU data exchange via link variable $A_DLx
Cross-NCU traversing of axes and spindles using link axes and container-link axes
Cross-NCU master value coupling of axes and spindles using lead-link axes
Safety Integrated
If axial Safety Integrated functions are active for a link axis, data that is not safety-related is
exchanged between the local safety axis (link axis on NCUx) and the channel that is
traversing it (NCUy) via the NCU link. This also enables Safety Integrated-supporting
functions for link axes, such as velocity/speed monitoring-dependent setpoint limiting and
higher-order stop functions (STOP D/E).
Note
The Safety Integrated functions "Safe software limit switch" (SE) and "Safe software cam,
safe cam track" (SN) are not (yet) supported.
Link module
The link communication requires optional link modules. A link module is an optional
PROFINET module for isochronous real-time communication (IRT) via Ethernet. The link
module occupies the option slot of the NCU.
Quantity structure
As standard, a maximum of three NCUs can be interconnected to form a link group.
Note
For a specific project, on request to your local regional Siemens representative, further
NCUs can be integrated to form a link group.
Extended Functions
2.1.2.2 Link variables

Link variables are global system user variables that for configured link communication can
be used by all NCUs of the network. Link variables can read and written in part programs,
cycles and synchronized actions.
The reading and writing of link variables is performed in the main run. A channel
synchronization is therefore performed implicitly with regard to the link variables so that all
channels read the same value in the same interpolator cycle. By comparison, global user
data (GUD) can also be used cross-channel like the link variables. However, as the GUD is
processed in the preprocessing, no implicit channel synchronization is performed here. If
necessary, GUD must therefore be synchronized by the user through specific programming.
Note
On systems without an NCU link, link variables can also be used as additional global user
data alongside standard global user data (GUD).
2.1.2.3 Link axes

Link axes enable the creation of distributed control systems, in which the setpoints of the
machine axes are not created by channels of the NCU to which the machine axes are
physically connected, but by channels of an arbitrary NCU of the link group.
Fixed assignment for link axes

The assignment, on which NCU the setpoints for which machine axis are created, is fixed for
link axes through the machine data configuration.
Variable assignment for container link axes

The assignment is variable for container link axes. A container link axis can therefore be
traversed alternatively by each NCU of the link group. See Section "Axis container
(Page 100)".
Irrespective of the assignment described above, the logical machine axis can be made
known to the link axis of several channels on the NCU generating the setpoint and then
functionally handled as a local logical machine axis, e.g. master value for position/feed
couplings, NCU-local axis interchange.
Extended Functions
2.1.2.4 Lead link axes

If in conjunction with the coupling functions of the generic coupling, all interpolators, i.e. the
setpoint-creating/processing channels, the leading and following axes/spindles, are on the
same NCU, the use of a lead link axis is not required. The machine axes of the leading
and/or following axes/spindles can also be connected link axes to different NCUs.
Application
A lead link axis is always required when not all interpolators of a coupling group are on the
same NCU. The lead link axis provides an image of the leading axis/spindle or the master
value for the local interpolators, on another NCU. Starting from this master value, the
setpoints of the following axes/spindles are then generated by the interpolators on this NCU.
Further application
A lead link axis is also used if more machine axes are involved in a coupling than are
available absolutely or relatively on an NCU for the coupling.
References
Special Functions Function Manual, Section "Axis couplings (M3)" > "Generic coupling"
2.1.2.5 Dependencies
In order that several axes can be traversed in an interpolatary relationship, it is essential that
the setpoints generated by the interpolator of the traversing channel be transferred to the
position control at the same time.
During the transfer of the setpoints via the NCU link, for example, for a link axis there is a
delay of one interpolator cycle in relation to the setpoint of a local axis. The delay must be
compensated by a suitable increase of the buffer between the interpolator and the position
controller :
MD18720 $MN_MM_SERVO_FIFO_SIZE = <value> = <default value + compensation value>
Function Compensation value

Link axis One interpolator cycle must be compensated on all NCUs with axes that
Container-link axis interpolate with a link or container link axis.
Compensation value = 1
Lead-link axis Two interpolator cycles must be compensated on the NCU of the leading
axis that generates the setpoints for the lead link axis.
Compensation value = 2
Note
In contrast to lead link axes, link and container link axes require another compensation value
(MD18720 $MN_MM_SERVO_FIFO_SIZE). With simultaneous use of link or container link
axes and lead link axes within a link group, the delays cannot be compensated.
Extended Functions
2.1.2.6 Application example: Rotary indexing machine

On the basis of rotary cycle machine with two NCUs, the application of the "NCU Link"
function is shown as example. The principal units of the rotary indexing machine are:
MTR rotary axis for the rotary table
MS1 - MS4 spindles
Machining stations 1 and 2, each with the X1 and Z1 linear axes
Loading and unloading station
All of the machine axes remain permanently assigned to their particular NCU. The same
axes (X and Z) and spindles (S1) are always addressed in the machining program of the
relevant NCU.
The workpiece status is represented schematically after each machining step.
For each machining step, the rotary table (MTR) advances one position counter-clockwise.
This so assigns the spindles to another station for each machining step. The changing
relationships of the spindles defined in the channels to the machine axes are represented as
an axis container in the NCU.
If the machine axis of a spindle is not contained on its own NCU, the spindle setpoints are
transferred by link communication to the associated NCU and output there at the machine
axis.
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Extended Functions
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Parameterization (schematic)
General
Programmed channel axes in the part programs of both NCUs: X, Z, S1
NCU1 Machine axes defined in the NCU:
Local: X1, Z1
Axis container: MS1, MS2
NCU2 Machine axes defined in the NCU:
Local: X1, Z1
Axis container: MS3, MS4
Initial setting Rotation of the MTR (rotary table) rotary

(Fig. 1) axis by one position
(Fig. 2)
NCU1 Machining station 1: X1, Z1, MS2
Diagram showing the channel axes programmed in the part program:
X X1 and Z Z1 X X1 and Z Z1
S1 MS2 S1 MS1
NCU2 Machining station 2: X1, Z1, MS2
Diagram showing the channel axes programmed in the part program:
X X1 and Z Z1 X X1 and Z Z1
S1 MS3 S1 MS2 (link axis)
Extended Functions
2.2 NCU link
2.2 NCU link
2.2.1 Link communication
2.2.1.1 General information
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The NCU-link communication cycle allows an interpolation-synchronous cross-NCU data

exchange for the following applications:
Cross-NCU link variable $A_DLx
All the NCUs involved with the NCU-link communication have a common view of the link
variables because they are exchanged via the NCU link interpolator cycle clock-
synchronous between the NCU of the link group.
Cross-NCU traversing of axes and spindles using link axes and container-link axes
If single or interpolation axis traversal is made from a channel of an NCU, NCU-link
setpoints can also be transferred to axes physically connected to another NCU of the link
group. These axes are designated as link axes.
Cross-NCU master value coupling of axes and spindles using lead-link axes
NCU1 traverses axis X1 (leading axis), the setpoints are transferred to a link axis of
NCU2 (lead-link axis) via the NCU link. Coupling of axis X2 is realized in NCU2 on this
lead-link axis. This means axis X2 is indirectly the following axis of X1.
Extended Functions
2.2 NCU link
Data transfer
Depending on the active functions, the following cyclic and non-cyclical data transmissions
occur between the NCUs involved with the link communication:
High-priority, cyclic data transfer:
Setpoints, actual values and status signals of the axes
NCU status signals
High-priority, non-cyclic, non-displaceable data transfer:
Non-safety-related data as part of the Safety Integrated function
States of the container axes during an axis container rotation
Low-priority, non-cyclic, displaceable data transfer (listed in order of decreasing priority):
Link variables
Warm restart requirements
Activation of axis container rotations
Changes in NCU-global machine and setting data
Activation of the axial machine data for link axes
Alarms
Displacement
If for low-priority, non-cyclic, displaceable data transmission not all requirements can be sent
in a single interpolator cycle, the request with higher priority displaces that with a lower
priority. This will then be sent later.
Quantity structure: NCU 7x0.3 PN

As standard, a maximum of three NCUs can be interconnected to form a link group.
Note
For a specific project, on request to your local regional Siemens representative an NCU-link
group with more than three NCUs is possible. Without project-specific supplements, more
than three NCUs are rejected with Alarm 380020.
Extended Functions
2.2 NCU link
NCU link and Safety Integrated

The following figure shows a constellation with two NCUs and two machine axes, of which
the MA2 machine axis of the NCU2 is traversed as link axis for NCU1. The Safety Integrated
function monitors the safety-related aspects of both axes.
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The safety-related input signals (F_DI) of both NCUs can be acquired, linked via the safe
programmable logic (SPL) and exchanged using the safety-related CPU-CPU
communication (FSend/FRecv).
As part of the Safety Integrated function, the NCU-link communication permits the single-
channel non-safety-related transfer of link axis data for Safety Integrated-supporting
functions.
Examples:
Interpolatory braking for an implicit Stop D of all traversing axes, including the link axes,
in the channel.
Reduce the speed of all axes traversing in the channel, including link axes, for a change
of the safe speed.
Extended Functions
2.2 NCU link
Safety Integrated acceptance test and NCU link

The Acceptance Test wizard (ATW) is generally used to perform the acceptance test
separately for each NCU. Only alarms on the home NCU of the axis are displayed for link
axes. To make the ATW also check alarms for link axes, the ATW must be told the safety-
relevant NCU connected via the NCU link. For this purpose, these must be entered in the
NETNAMES.INI file on the PG/PCU on which the ATW runs.
Example: Entries in the NETNAMES.INI file for NCU link with two safety-relevant NCUs
Adapt file: NETNAMES.INI (excerpt)

[own]
owner = HMI_1
[conn HMI_1]
conn_1= NCU_1
conn_2= NCU_2
[param HMI_1]
mmc_address = 1
[param network]
[param NCU_1]
nck_address= 192.168.214.2,LINE=10,NAME=/NC,SAP=030d,PROFILE=CLT1__CP_L4_INT
plc_address= 192.168.214.2,LINE=10,NAME=/PLC,SAP=0201,PROFILE=CLT1__CP_L4_INT
ADDRESS2= 192.168.214.2,LINE=10,NAME=/CP,SAP=0501,PROFILE=CLT2__CP_L4_INT
ADDRESS10= 192.168.214.2,LINE=10,NAME=/DRIVE_00_000,SAP=0201,SUBNET=0000-
00000000:000,PROFILE=CLT2__CP_L4_INT
ADDRESS11= 192.168.214.2,LINE=10,NAME=/DRIVE_03_003,SAP=0900,PROFILE=CLT2__CP_L4_INT
ADDRESS12= 192.168.214.2,LINE=10,NAME=/DRIVE_03_011,SAP=0B00,PROFILE=CLT2__CP_L4_INT
ADDRESS13= 192.168.214.2,LINE=10,NAME=/DRIVE_03_012,SAP=0C00,PROFILE=CLT2__CP_L4_INT
ADDRESS14= 192.168.214.2,LINE=10,NAME=/DRIVE_03_013,SAP=0D00,PROFILE=CLT2__CP_L4_INT
ADDRESS15= 192.168.214.2,LINE=10,NAME=/DRIVE_03_014,SAP=0E00,PROFILE=CLT2__CP_L4_INT
ADDRESS16= 192.168.214.2,LINE=10,NAME=/DRIVE_03_015,SAP=0F00,PROFILE=CLT2__CP_L4_INT
name=Machine_1
[param NCU_2]
nck_address= 192.168.214.1,LINE=10,NAME=/NC,SAP=030d,PROFILE=CLT1__CP_L4_INT
plc_address= 192.168.214.1,LINE=10,NAME=/PLC,SAP=0201,PROFILE=CLT1__CP_L4_INT
ADDRESS2= 192.168.214.1,LINE=10,NAME=/CP,SAP=0501,PROFILE=CLT2__CP_L4_INT
ADDRESS10= 192.168.214.1,LINE=10,NAME=/DRIVE_00_000,SAP=0201,SUBNET=0000-
00000000:000,PROFILE=CLT2__CP_L4_INT
ADDRESS11= 192.168.214.1,LINE=10,NAME=/DRIVE_03_003,SAP=0900,PROFILE=CLT2__CP_L4_INT
ADDRESS12= 192.168.214.1,LINE=10,NAME=/DRIVE_03_011,SAP=0B00,PROFILE=CLT2__CP_L4_INT
ADDRESS13= 192.168.214.1,LINE=10,NAME=/DRIVE_03_012,SAP=0C00,PROFILE=CLT2__CP_L4_INT
ADDRESS14= 192.168.214.1,LINE=10,NAME=/DRIVE_03_013,SAP=0D00,PROFILE=CLT2__CP_L4_INT
ADDRESS15= 192.168.214.1,LINE=10,NAME=/DRIVE_03_014,SAP=0E00,PROFILE=CLT2__CP_L4_INT
ADDRESS16= 192.168.214.1,LINE=10,NAME=/DRIVE_03_015,SAP=0F00,PROFILE=CLT2__CP_L4_INT
name=Machine_2
References
The "Safety Integrated" function is described in detail in:
Function Manual for Safety Integrated
Extended Functions
2.2 NCU link
2.2.1.2 Link module

The NCU-link communication takes place via link modules A link module is an optional
PROFINET module for isochronous real-time communication (IRT) via Ethernet. The link
module can be used only for the NCU-link communication. It is not possible to use a link
module for general PROFINET communication.
The option slot is required on the NCU module for the link module.
Note
There is only one option slot on the NCU module. This prevents the parallel use of an NCU-
link module and other optional modules.
Link module and NCU modules

The Communication Board Ethernet CBE30-2 is available as link module for the "NCU710.3
PN", "NCU720.3 PN" and "NCU730.3 PN" NCU modules. The option slot is required on the
NCU module for the link module.
References
Manual NCU7x0.3 PN; "Connectable components" > "CBE30-2" section
2.2.1.3 Parameter assignment: NC system cycles

As basic requirement for link communication, the following system cycle clocks must be set
the same in all NCUs involved in the NCU group:
Basic system cycle clock
Position control cycle clock
Interpolator cycle clock
Basic system cycle clock

The DP cycle set for isochronous communication in the STEP 7 project is used as basic
system cycle clock. The current basic system cycle clock is displayed in machine data:
MD10050 $MN_SYSCLOCK_CYCLE_TIME
Note
Manual alignment across several communications buses
If several isochronous communication buses (PROFIBUS 1 ... n, PROFINET 1 ... m) have
been configured on an NCU, the same DP cycle time in STEP 7 HW Config must be set for
each communication bus.
Depending on the position control cycle clock
For the SINUMERIK 840D sl, the ratio between the basic system cycle clock and the position
control cycle clocks is fixed (1:1) and cannot be changed. Because only certain position
control cycle clocks can be set for the NCU link, only these position control cycle clocks can
be set as the basic system cycle clock or DP cycle time. See the next paragraph "Position
control cycle clock".
Extended Functions
2.2 NCU link
Position control cycle clock

The position control cycle clock is set as a ratio to the basic system cycle clock. For the
SINUMERIK 840D sl, the ratio is fixed (1:1) and cannot be changed. The current position
control cycle clock is displayed in the machine data:
MD10061 $MN_POSCTRL_CYCLE_TIME
Note
Permitted position control cycle clocks
For the NCU link, depending on the number of NCUs in the link group, only the following
position control cycle clocks [ms] are set:
2 NCU: 2.0, 2.5, 3.0, 3.5, 4.0
3 NCU: 3.0, 3.5, 4.0
See Section "Configuration (Page 85)".
Interpolator cycle clock

The interpolator cycle clock is set as a ratio of the basic system cycle clock. The setting is
made via the following machine data:
MD10070 $MN_IPO_SYSCLOCK_TIME_RATIO
The actual interpolator cycle clock is displayed in machine data:
MD10071 $MN_IPO_CYCLE_TIME
Notes on setting
Cycle clock settings

It is recommended the following settings are made:
The default 90% setting for the CPU time share of the NCK should be retained:
MD10185 $MN_NCK_PCOS_TIME_RATIO
The system cycle clocks must be set so that the average system utilization caused by the
interpolator and the position controller does not exceed 60% in normal program
operation. As maximum value, 90% should be not be exceeded.
Note:
In special circumstances, maximum values > 100% can be displayed.
Lowest cyclic communication load

The lowest cyclic communication load during the link communication results for a cycle clock
ratio of interpolator cycle clock to position control cycle clock of 1:1. With activated "Dynamic
Servo Control (DSC)" drive function, this is generally the most effective setting.
Disadvantage: No telegram repetitions are possible for the link communication.
Extended Functions
2.2 NCU link
Time frame of the NC/PLC interface update

The following setting is active during the run-up of all NCUs involved in the link group:
MD18000 $MN_VDI_UPDATE_IN_ONE_IPO_CYCLE = 1
This causes the NC/PLC interface to be read and written completely in just one interpolation
cycle.
2.2.1.4 Parameter assignment: Link communication
NC-specific machine data
Number Identifier $MN_ Meaning

MD12510 NCU_LINKNO Unique numerical identification of the NCU within the link group. The
identifiers must be assigned without any gaps in ascending ordering
starting from 1.
Value range: 1, 2, ... Maximum NCU number
Note:
The NCU to which the value 1 is assigned as NCU identification is the
master NCU of the link group. The parameterization of link axes and
axis containers may only be made with the machine and setting data of
the master NCU.
MD18780 MM_NCU_LINK_MASK.Bit 0 Activation of the link communication
MD18781 NCU_LINK_CONNECTIONS Number of internal link connections
Note:
It is recommended to retain the default value 0 (determination of the
number by the NC).
MD18782 MM_LINK_NUM_OF_MODULES Number of NCUs to be connected with one another via NCU link.
2.2.1.5 Configuration
The NC system software supplies specific configurations for each supported combination of
NCU number and position controller cycle of a link group (see section "Parameter
assignment: NC system cycles (Page 83)").
During the system startup, the appropriate configuration will be loaded (as specified by the
values parameterized in the machine data):
MD18782 $MN_MM_LINK_NUM_OF_MODULES (number of NCUs of the line group))
MD10061 $MN_POSCTRL_CYCLE_TIME (position controller cycle)
Note
For applications, in which the standard configurations that have been supplied cannot be
used, please contact your local Siemens sales person.
Extended Functions
2.2 NCU link
2.2.1.6 Wiring the NCUs

The numerical sequence of the NCUs within a link group is defined in the NCUs using the
following machine data:
MD12510 $MN_NCU_LINKNO = <NCU number>, with NCU number = 1 ... max. NCU
number
Cabling
Starting from the NCU1, the NCU link modules should be wired up in the NCU number
sequence according to the following schematic: NCU(n), Port 0 NCU(n+1), Port 1
1&8OLQNYLD352),1(7 1&8OLQNYLD352),1(7
3RUW
3RUW
3RUW
3RUW
3RUW
3RUW
3RUW
3RUW
3RUW
3RUW
3RUW
3RUW
1&8 1&8 1&8
/LQNPRGXOH /LQNPRGXOH /LQNPRGXOH
1&8 1&8 1&8Q
Figure 2-6 Wiring schematic, NCU link
2.2.1.7 Activation
The link communication is activated using the following machine data:
MD18780 $MN_ MM_NCU_LINK_MASK, Bit 0 = 1
Note
Activation time
It is recommended to activate the link communication only after complete commissioning of
the entire functionality on all participating NCUs has been done.
Extended Functions
2.2 NCU link
2.2.2 Link variables

Complex systems with several NCUs require for the complete system coordination of the
manufacturing processes a cyclic exchange of user-specific data between the NCUs. The
data exchange is performed via the link communication and a special memory area, the link
variables memory available for each NCU.
The size and data structure of the link variables memory can be specified for each specific
user. The data stored in the link variables memory is addressed using a special $A_DLx link
variable.
These are system-global user variables that can be read and written in part programs and
cycles by all NCUs involved in a link group if link communication has been configured. Unlike
global user variables (GUD), link variables can also be used in synchronized actions.
1&8OLQNYLD352),1(7
1&8 1&8 1&8 1&8

/LQNPRGXOH /LQNPRGXOH
&KDQQHO /LQNYDULDEOH /LQNYDULDEOH

PHPRU\ PHPRU\
1$B'/[>@
Figure 2-7 Link variables
Requirement
The use of link axes requires a link communication defined in accordance with "Section Link
communication (Page 79)".
Link variable as NCU-global user variable
Note
If an NCU Is not a node of a link group or the link variables are not required for
communication via NCU link, the link variables can be used as the NCU-global user
variables.
Extended Functions
2.2 NCU link
2.2.2.1 Properties of the link variables memory
Parameterizing the memory size

The size of the link variables memory in bytes is set with the following machine data:
MD18700 $MN_MM_SIZEOF_LINKVAR_DATA (size of the link variables memory)
The setting for the size of the link variables memory should be identical for all NCUs involved
in the link group. If the memory sizes are different, the largest value assigned is used.
Initialization
After an NCU is powered up, the link variables memory is initialized with 0.
Structure
From the point of view of the system, the link variables memory is an unstructured memory
area that is available for link communication purposes. The link variables memory is
structured by the user/machine manufacturer alone. Depending on how the data structure is
defined, the link variables memory is accessed by means of data format-specific link
variables.
System-wide alignment
Once a link variables memory has been written to, the changes that have been made to the
data are transferred to the link variables memories of all other NCUs involved in the link
group. The link variables memories are usually updated by means of link communication
within two interpolation cycles.
2.2.2.2 Properties of the link variables

The link variables memory is accessed via the following data format-specific link variables:
Data type 1) Designation Data format 2) Bytes 2) Index i 3) Value range

UINT $A_DLB[ i ] BYTE 1 i=n*1 0 ... 255
INT $A_DLW[ i ] WORD 2 i=n*2 -32768 ... 32767
INT $A_DLD[ i ] DWORD 4 i=n*4 -2147483648 ... 2147483647
REAL $A_DLR[ i ] REAL 8 i=n*8 (2,2*10-308 1,8*10+308)
1) Data type of link variables when used in part program/cycle
2) Data format of link variables or number of bytes addressed by the link variables in the link variables memory
3) The following must be noted for index i:
Index i is a byte index that relates to the beginning of the link variables memory.
The index must be selected so that the bytes addressed in the link variables memory are located on a data format limit
index i = n * bytes, where n = 0, 1, 2, etc.
$A_DLB[i]: i = 0, 1, 2, ...
$A_DLW[i]: i = 0, 2, 4, ...
$A_DLD[i]: i = 0, 4, 8, ...
$A_DLR[i]: i = 0, 8, 16, ...
Extended Functions
2.2 NCU link
Write
A link variable is written with main-run synchronism.
Read
A preprocessing stop is initiated when a link variable is read.
Checks
The following checks are performed for the link variables and link variables memory:
Observance of the value range limits
Access to format limit
Observance of defined memory area in link variables memory
The user/machine manufacturer is solely responsible for preventing the following errors:
Accessing with incorrect data format
Accessing the wrong address (index i)
Reciprocal overwriting of the same data item by multiple channels of a single NCU or
different NCUs
Reading a data item before it has been updated by a channel of its own NCU or of a
different NCU
Note
Data consistency
The user/machine manufacturer is solely responsible for ensuring data consistency within
the link variables memory, both on a local-NCU basis and across NCUs.
2.2.2.3 Write elements

In the case of write access to the link variables memory (e.g. $A_DLB[4] = 21), what is
known as a link variables write element is required for managing the write process within the
system. The maximum number of write elements that are available for each interpolation
cycle is set by means of the following machine data:
MD28160 $MC_MM_NUM_LINKVAR_ELEMENTS
The maximum number of write elements thus restricts the number of link variables that can
be written during each interpolation cycle.
Extended Functions
2.2 NCU link
2.2.2.4 Dynamic response during write

The link variables are written with main-run synchronism. The new value may be read by the
other channels in its own NCU no later than the next interpolation cycle. It can be read in the
next part program block in its own channel.
The channels of the other NCUs in the link group normally see the new value after two
interpolation cycles. However, the limited bandwidth can lead to delays in transferring write
requests to the other NCUs in the link group (message delays). Causes for a message delay
can be:
Writing a large number of link variables in an interpolation cycle
Writing link variables and a the request for an axis container rotation in the same
interpolator cycle
Writing link variables and transferring an alarm in the same interpolation cycle
2.2.2.5 System variable
NC-specific system variable
Identifier Meaning
$AN_LINK_TRANS_RATE_LAST The number of write requests that were still free
in the last interpolator cycle.
$AN_LINK_TRANS_RATE_LAST_SUM[<n>] The number of write requests that were still free
in the last interpolator cycle in the send direction
to the specified NC <n> (NCU number).
$AN_LINK_CONN_SIZE_LINKVAR The number of bytes to be transferred for a write
request of a link variable.
$AN_LINK_CONN_SND[<n>] The maximum number of bytes that can be
transferred per interpolator cycle from the current
NCU to the specified NCU.
$AN_LINK_CONN_RCV[<n>] The maximum number of bytes that can be
transferred per interpolator cycle from the
specified NCU to the current NCU.
<n>: NCU number according to MD12510 $MN_NCU_LINKNO of the relevant NCU
Note for: $AN_LINK_CONN_SIZE_LINKVAR

The writing of a link variable causes the number of bytes specified in
$AN_LINK_CONN_SIZE_LINKVAR to be transferred via the not-cyclic link communication.
The number is independent of the format of the link variables.
The maximum number of write requests that can be transferred to the specified NCU for
each interpolator cycle is calculated as:
Max. number of write requests = $AN_LINK_CONN_SND[<n>] /
$AN_LINK_CONN_SIZE_LINKVAR
Extended Functions
2.2 NCU link
Channelspecific system variable
Identifier Meaning
$A_LINK_TRANS_RATE 1) Number of write requests that still can be
transferred in the current interpolator cycle.
1) Application example, refer to Section: "Synchronization of a write request (Page 91)"
2.2.2.6 Synchronization of a write request

If certain applications require the new value of a link variable to be transferred to the other
NCUs in the link group in precisely two interpolation cycles, writing to the link variable must
be made in a synchronized action. In the synchronized action, writing to the link variable is
only executed if in the actual interpolator cycle, the write request can still be executed. The
$A_LINK_TRANS_RATE system variable contains the number of write requests that can still
be transferred in the current interpolator cycle.
In the following example, a link variable, data type WORD (2 bytes) and a link variable, data
type DWORD (4 bytes), are written:
Program example
N120 WHEN $A_LINK_TRANS_RATE > 0 DO $A_DLW[0] = 9
N125 WHEN $A_LINK_TRANS_RATE > 0 DO $A_DLD[2] = 7
N130 G4 F1
The synchronized action in N120 is performed only when the write request can be transferred
in the same interpolator cycle to the other NCU of the link group. In this case, the
$A_LINK_TRANS_RATE system variable is also decremented in the same interpolator cycle
so that the updated value is available for the synchronized action in the following N125 block.
2.2.2.7 Example: Structure of the link variables memory

The following data are defined for the link communication:
Data format Number Bytes per data Bytes required

BYTE 2 1 2
WORD 1 2 2
DWORD 3 4 12
REAL 1 8 8
required size of the link variables memory: 24
Extended Functions
2.2 NCU link
Memory structure
The data is arranged in the link variables memory as follows, with the data format limits
taken into account:
/LQNYDULDEOHVPHPRU\
0'01B00B6,=(2)B/,1.9$5B'$7$
,QGH[ %<7( %<7( :25' ':25'
':25' ':25'
5($/
Figure 2-8 Example: Structure of the link variables memory
Note
Memory structure
The data in the link variables memory is always arranged randomly and may therefore
appear different (although the data format limits will still be taken into account).
Access via a link variable must be programmed as follows, in accordance with the memory
structure defined:
Program code Description

$A_DLB[0] ; BYTE(1)
$A_DLB[1] ; BYTE(2)
$A_DLW[2] ; WORD
$A_DLD[4] ; DWORD(1)
$A_DLR[16] ; REAL
Extended Functions
2.2 NCU link
2.2.2.8 Example: Read drive data
Task
A system contains two NCUs (NCU1/NCU2). The NCUs are connected via the NCU link.
The MA2 machine axis of NCU1 (drive 2) travels in interpolation mode as link axis for NCU2.
The actual current value of drive 2 should be transferred for evaluation from NCU1 to NCU2.
The figure below shows the basic design of the system.
1&8OLQNYLD352),1(7
1&8 1&8 1&8 1&8

/LQNPRGXOH /LQNPRGXOH
1&B$;
/RJPDFKLQHD[LVLPDJH
$;
$;
$;
$;
$;
0'
01B$;&21)B/2*,&B0$&+$;B7$%
0DFKLQHD[HV
0$
0$
0$
0$
0$
0$
0$
0'
01B$;&21)B0$&+$;B1$0(B7$%
'ULYH
'ULYH
'ULYH
'ULYH
'ULYH
'ULYH
Requirement
The actual current value for drive 2 (NCU1/MA2) can be read via the $VA_CURR system
variable. In the case of PROFIdrive-based drives, the following machine data item needs to
be set for this purpose:
MD36730 $MA_DRIVE_SIGNAL_TRACKING = 1 (acquisition of additional actual drive
values)
Setting the machine data makes the following drive actual values available:
$AA_LOAD, $VA_LOAD (drive capacity utilization in %)
$AA_POWER, $VA_POWER (drive active power in W)
$AA_TORQUE, $VA_TORQUE (drive torque setpoint in Nm)
$AA_CURR, $VA_CURR (actual current value of axis or spindle in A)
Extended Functions
2.2 NCU link
Programming
NCU1
A static synchronized action is used to write cyclically in the interpolation cycle the actual
current value $VA_CURR of axis 2 (NCU1/MA2) via the link variable $A_DLR[0] (REAL
value) to the first 8 bytes of the link variables memory:
Program code
IDS=1 WHENEVER TRUE DO $A_DLR[0]=$VA_CURR[MA2]
NCU2
With a static synchronized action, the transferred actual current value is read cyclically in the
interpolator cycle via link variable $A_DLR[0]. If the actual current value is greater than 23 A,
alarm 61000 is displayed.
Program code
IDS=1 WHEN $A_DLR[0] > 23.0 DO SETAL(61000)
2.2.3 Link axes

A link axis is designated as a machine axis for which the setpoints are generated by a
different NCU than that to which the machine axis is physically connected. Link axes in
conjunction with axis containers (see Section "Axis container (Page 100)") permit in complex
plants, such as rotary indexing machines with several NCUs, the alternate use of machine
axes of the NCU of the link group.
The following figure shows as example an MA1 machine axis connected to the NCU1. The
MA2 machine axis is connected to the NCU2. The X and Z channel axes travel in
interpolation mode by a part program that runs in a channel of NCU1. The setpoints are
generated in the NCU1 interpolator. For machine axis MA1, they are forwarded to the
position control of the NCU1. For machine axis MA2, they are transferred via the NCU link to
the position control of the NCU2 and output there to the drive.
Extended Functions
2.2 NCU link
1&8OLQN
1&8 1&8
&KDQQHO
1*)
1;=
&KDQQHOD[HV
0'
;
0&B$;&21)B&+$1$;B1$0(B7$%
1&B$;
/RJPDFKLQHD[LVLPDJH
$;
$;
$;
0'
01B$;&21)B/2*,&B0$&+$;B7$%
0DFKLQHD[HV
0$
0$
0'
;
01B$;&21)B0$&+$;B1$0(B7$%
'ULYH
'ULYH
/RFDOD[LV /LQND[LV
Figure 2-9 Link axes
Requirement
The use of link axes requires a link communication defined in accordance with "Section Link
communication (Page 79)".
Home NCU
The home NCU of a link axis is the NCU on which it is physically connected as machine axis.
The position control and the exchange of axial NC/PLC interface signals of a link axis always
occurs on the home NCU. The generation of the setpoint can in principle be performed on
any NCU of the link group.
In the above figure:
NCU1: Home NCU of machine axis MA1
NCU2: Home NCU of machine axis MA2
Extended Functions
2.2 NCU link
2.2.3.2 Name of a link axis

The name of a link axis is composed of the identifier for the home NCU on which the
machine axis is physically connected and the general machine axis name AXn:
NC<ID>_<axis>
<ID>: Identification of the NCU of the link group in accordance with:

MD12510 $MN_NCU_LINKNO
See Section "Parameter assignment: Link communication (Page 85)"
<axis>: General machine axis name: AX1, AX2, AX3, ...
2.2.3.3 Parameterization
Assignment: Geometry axis or special axis to link axis
Direct assignment
A geometry or special axis can be assigned directly to a link axis in the logical machine axis
image by specification of the link axis name:
MD10002 $MA_AXCONF_LOGIC_MACHAX_TAB[ <axis>] = <link axis>
Parameters Meaning
<axis>: Machine axis index: 0, 1, 2, (max. number of machine axes - 1)
<link axis>: Name of the link axis: NCx_AXy, see Section "Name of a link axis (Page 96)"
Indirect assignment
A geometry or special axis can be assigned to a link axis indirectly in the logical machine
axis image by specification of a container slot. The container slot then contains the actual
name of the link axis, as described above. This is called a container-link axis. See also
Section: "Axis container (Page 100)".
Synchronous setpoint output

A delay of one interpolator cycle results during the transfer of the setpoints of a link axis for
the setpoint-generating NCU to the home NCU. To ensure that the setpoints for the
interpolation of local axes and link axes are output to the drives at exactly the same time, this
delay must be compensated. To do this, on the setpoint-generating NCU, the number of
buffer elements of the buffer between the interpolator and the position controller must be set
one element larger than the number of buffer elements of the home NCU:
MD18720 $MN_MM_SERVO_FIFO_SIZE= 3
Extended Functions
2.2 NCU link
Example
1&8
*HRPHWU\D[LVQDPH *HRPHWU\D[HVXVHGLQWKHFKDQQHO &KDQQHOD[LVQDPH
0' 0' 0'
0&B$;&21)B*(2$;B1$0(B7$% 0&B$;&21)B*(2$;B$66,*1B7$% 0&B$;&21)B&+$1$;B1$0(B7$%
&KDQQHO &KDQQHO &KDQQHO
; ;
= =
VWJHRPHWU\D[LV>@ ; VWFKDQQHOD[LV>@ ;

QGJHRPHWU\D[LV>@ = QGFKDQQHOD[LV>@ =
UGJHRPHWU\D[LV>@ UGFKDQQHOD[LV>@

0DFKLQHD[HVXVHGLQWKHFKDQQHO /RJLFDOPDFKLQHD[LVLPDJH
0'0&B$;&21)B0$&+$;B86(' 0'01B$;&21)B/2*,&B0$&+$;B7$%

&KDQQHO
1&B$;
1&B$;
&KDQQHO
$;
$;

Figure 2-10 Example: Parameterization of link axes
Channel 1
The local AX1/AX2 machine axes of the NCU1 are assigned to the X/Z geometry axes.
Channel 2
The NC2_AX1/NC2_AX2 link axes of the NCU2 are assigned to the X/Z geometry axes.
2.2.3.4 Auxiliary function output for spindles

During program execution and after block search with "search via program test"
(SERUPRO), the pre-defined auxiliary functions S, M3, M4, M5, M19 and M70 are output
channel-specific on the NCU on which the spindle has been programmed and also axis-
specific on the home NCU.
Output of the channel-specific auxiliary functions

DB21, ... DBW68 (extended address of the M function)
DB21, ... DBD70 (M function 1)
DB21, ... DBW98 (extended address of S function 1)
DB21, ... DBD100 (S function 1)
Extended Functions
2.2 NCU link
Output of the axis-specific auxiliary functions

DB31, ... DBD78 (F function for axis)
DB31, ... DBW86 (M function for spindle)
DB31, ... DBD88 (S function for spindle)
References
Detailed information about the auxiliary function output can be found in:
Function Manual, Basic Functions, "Help function outputs to the PLC (H2)" section
Maximum number of machine axes

Even for the use of link axes, as previously, the maximum number of concurrently-usable
geometry and special axes as well as machine axes are still available for each NCU type.
"Lead link axes and "link axes" functions

As the functions "lead link axes" and "link axes" require different settings in machine data
MD18720 $MN_MM_SERVO_FIFO_SIZE, they cannot be used within a link group at the
same time.
Alarms: General behavior

If an error is detected at the position control level of the home NCU of a link axis and the
relevant alarm does not have "NC not ready" as response, the alarm is transferred via the
NCU link to the setpoint-generating NCU and then output.
Alarms: Behavior for emergency stop

If an emergency stop request is activated for an NCU via the NC/PLC interface, all axes
physically connected to this NCU will be switched to the "follow-up" mode. This also affects
link axes whose setpoints are currently generated by other NCUs. Under the assumption that
no further practical machining operations are then possible on these NCUs, an additional
alarm will be generated that stops all dependent axis movements.
Alarm acknowledgement
This additional alarm must be acknowledged by an NC reset. If the original alarm is still
active at this time, although the additional alarm can be acknowledged, an additional self-
clearing alarm will be generated that prevents a traversal of the axes or a program start until
the original alarm has been acknowledged.
Extended Functions
2.2 NCU link
Alarms: Response for "NC not ready" alarm response

If an error is detected at the position control level of the home NCU of a link axis and the
relevant alarm does not have "NC not ready" as response, the alarm is transferred to the
setpoint-generating NCU via the NCU link and output there. The alarm output is also made
on the home NCU.
Under the assumption that no further practical machining operations are then possible on the
setpoint-generating NCU, an additional alarm will be generated that stops all dependent axis
movements.
Alarm acknowledgement
See alarm acknowledgement under "Alarms: Behavior for emergency stop"
Alarms: Behavior for "Mode group not ready" alarm response

If an error is detected within a mode group with several channels and the relevant alarm has
"Mode group not ready" as response, this causes the traversing movements in all channels
of the mode group to stop. If the traversing movements are generally independent of each
other, the response via the following machine data item can be changed to "Channel not
ready":
MD11412 $MN_ALARM_REACTION_CHAN_NOREADY = TRUE
Effect
In the NC/PLC interface, instead of signal DB11 DBX26.3 (mode group ready), the signal
DB21, DBX36.5 (channel ready), is reset.
Advantage
The alarm response remains limited to the channel in which the error is detected. If required,
the PLC user program can initiate further responses.
Requirement
There is no higher-priority alarm response than "Mode group not ready".
Compensations
The following compensations are not available:
Link axes: Quadrant error compensation (QEC)
Container link axes: Sag compensation (CEC)
Switch-off an NCU in a link group

If an NCU in a link group is switched off, the machining on all other NCUs of the link group
will be cancelled and an alarm issued.
Extended Functions
2.2 NCU link
Powering up an NCU group

If an NCK reset is triggered on an NCU in a link group, it will also be transferred to all other
NCUs of the link group so that all NCUs of the link group perform a warm restart.
Nibbling and punching technologies

The fast inputs/outputs required for the nibbling and punching must be connected and
parameterized on the NCU on which the part program is processed and the axes
interpolated. The commands for "High-speed nibbling and punching", e.g. PONS and SONS, are
not available for link axes.
Frames
A link axis is permitted in a Frame command only when it is a geometry axis. The Frame
command changes only the geometry in the channel to which the link axis is currently
assigned.
Speed/torque coupling, master-slave

The drives of all axes/spindles of a master-slave group must be connected to the same
NCU. The master axis can, however, be traversed as link axis for the channel of another
NCU.
2.2.4 Axis container

An axis container is a circular data structure with a parameterized number of elements.
These elements together with axis containers, are designated as slots (Slot 1, Slot 2, ... Slot
n). The slots allow a variable assignment of geometry and/or special axes to machine axes.
The entry in a slot can reference an NCU-local machine axis (container axis) or a link axis
(container-link axis).
The following figure shows an axis container with four slots. The container axes refer in the
current position of the axis container to the following machine axes:
Container axis Machine axis

CT1_SL1 NCU 1: AX1
CT1_SL2 NCU 1: AX2
CT1_SL3 NCU 2: AX1
CT1_SL4 NCU 2: AX2
Extended Functions
2.2 NCU link
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Rules
The following rules must be observed with regard to axis containers:
All machine axes of an axis container may be assigned to just one channel axis at any
one time.
Multiple slots of an axis container must not reference the same machine axis.
At any one time, only one channel is authorized to write to a machine axis, directly or via
a container axis.
Several geometry and/or special axes of a channel can also be assigned to the container
axes of an axis container.
Assignment: Geometry or special axis container axis

In the logical machine axis image MD10002 $MN_AXCONF_LOGIC_MACHAX_TAB, a
container axis can be assigned as a machine axis via container and slot to a geometry or
special axis, e.g. CONTAINER "CT1", slot "1":
MD10002 $MN_AXCONF_LOGIC_MACHAX_TAB[ n ] = CT1_SL1
During the traversing of the geometry or special axis, the machine axis assigned at this time
to slot 1 then traverses.
Axis container rotation

An axis container rotation is always performed when all channels involved on the axis
container have granted their enable with a program command. After the axis container
rotation, other machine axes are assigned to the geometry or special axes of the channels.
The setting data specifies the increment of an axis container rotation.
See Section "Parameterization (Page 103)".
Extended Functions
2.2 NCU link
Axis container name

The following program commands can be addressed via the axis container name (<axis
container>):
Program commands:
AXCTSWE(<axis container>)
AXCTSWED(<axis container>)
AXCTSWEC(<axis container>)
The following names are possible:
CT<container number>: The number of the axis container is attached to the CT letter
combination.
Example: CT3
<container name>: Individual name of the axis container set using
MD12750 $MN_AXCT_NAME_TAB
Example: A_CONT3
<axis name>: Axis name of a container axis which is known in the channel
involved.
Implicit wait
There is an implicit wait for the completion of a requested axis container rotation if one of the
following events has occurred:
Part program language commands which will cause a container axis assigned to this axis
container in this channel to move
GET(<channel axis name>) on a corresponding container axis
The next AXCTSWE(<axis container>) for this axis container
Note
Even an IC(0) will result in a wait including synchronization where necessary (block-by-
block change in addressing according to incremental dimension even though an absolute
dimension has been set globally).
Extended Functions
2.2 NCU link
Synchronization with axis position

If the new container axis assigned to the channel after a container rotation does not have the
same absolute machine position as the previous axis, then the container is synchronized
with the new position (internal REORG).
Note
SD41700 $SN_AXCT_SWWIDTH[<axis container>] is only updated for a new configuration.
If, after incremental rotation of the RTM/MS, the position of a circuit before the initial position
is reached, the container can be rotated normally in the forward direction to reach the initial
position of the container again. The drum or rotary table must however be turned back to the
original position, so that measuring and supply cables are not twisted.
See also
System variable (Page 111)
Programming (Page 110)
Machine data

MD12750 AXCT_NAME_TAB Name of the axis container
MD12760 AXCT_FUNCTION_MASK.Bit x Axis container-specific functions
MD1270x AXCT_AXCONF_ASSIGN_TABx Assignment of machine axes to the slots of an axis container
MD18720 MM_SERVO_FIFO_SIZE Size of the IPO/SERVO data buffer
Note:
The value 3 must be set on all participating NCUs for cross-NCU axis
containers.
Name of the axis container

MD12750 $MN_AXCT_NAME_TAB[ <index> ] = "<name>"
Parameters Meaning
<index>: 0, 1, max. axis container index
<name>: Name of the axis container (e.g. CT1)
Extended Functions
2.2 NCU link
Axis container-specific functions

MD12760 $MN_AXCT_FUNCTION_MASK.Bit x = <value>
Parameters <value> Meaning

Bit 0: 0 For a direct axis container connection (AXCTSWED), all other
channels must be in the RESET state.
1 For a direct axis container connection (AXCTSWED), only other
channels that have the interpolation authorization to axes of the axis
container need to be in the RESET state.
The machine data is used to activate the axis container-specific functions.
Assignment of machine axes to the slots of an axis container

MD1270x $MN_AXCT_AXCONF_ASSIGN_TABx[ <index> ] = <axis>
Parameters Meaning
x: 1 max. number of axis containers
<index>: 0, 1, max. slot index
<axis>: Machine axis name of a local machine axis (e.g. AX1)
Name of a link axis. See Section "General information (Page 94)".
The slots within an axis container must be assigned in ascending order without gaps, starting
with slot index 0.
Setting data
Increment of an axis container rotation

SD41700 $SN_AXCT_SWWIDTH[<index>]=<increment>
Parameters Meaning
<index>: 0, 1, max. axis container index
<increment>: Number of slots through which the axis container rotates
Illustration of the axis container rotation

The axis container rotation is enabled by means of program commands. See Section
"Programming (Page 110)".
In the following Fig. 1 (left-hand side), the NCU1_AX1 link axis is assigned as example to
slot 1 in the Initial setting axis container.
After the rotation with increment of 1 (Fig. 1, right-hand side), the NCU2_ AX2 link axis is
assigned to slot 1.
Extended Functions
2.2 NCU link
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Starting with the initial setting, after the rotation with increment 2 (Fig. 2, left-hand side), the
NCU2_ AX1 link axis is assigned to slot 1.
Starting with the initial setting, after the rotation with increment -1 (Fig. 2, right-hand side),
the NCU1_AX2 link axis is assigned to slot 1.
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Axis container with container-link axes

The parameterization of an axis container that contains container-link axes must be made on
the master NCU of the link group (MD12510 $MN_NCU_LINKNO == 1).
Extended Functions
2.2 NCU link
Alignment of axial machine data

For container axes, all axial machine data marked with the "CTEQ" (container equal)
attribute must have the same value for all container axes. Any different values will be aligned
automatically.
Control startup
During the control startup, all machine data will be aligned to the values of the container axis
of the first slot. If the value of a machine data item changes, the following message will be
displayed: "The axial machine data of the axes in axis container <n> has been adapted".
Activate machine data

If a machine data item of any container axis is changed, the new value also becomes
immediately available in all other container axes. The following message is displayed:
"Caution: This MD will be set for all container axes".
Slot change
If a slot of an axis container is assigned another machine axis, (MD127xx
AXCT_AXCONF_ASSIGN_TAB<x>), the following message is displayed: "The machine data
of the axes in axis container <n> will be adapted at the next startup".
Note
Container-link axes
For container-link axes, a machine data alignment is performed for all NCUs of the link group
involved on the axis container.
Parameter example
Assumptions
NCU Components
NCU1: Channel 1, X/Z geometry axes 1st/2nd channel axis
Channel 2, X/Z geometry axes 1st/2nd channel axis
Machine axes: AX1, AX2
CT1 axis container with four slots
NCU2: Machine axes: AX1, AX2
Extended Functions
2.2 NCU link
Parameter assignment: NCU1
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Effect
By programming the X and Z geometry axes in the 1st and 2nd channel of the NCU1, the
following axes traverse in the current position of the container:
The local AX1 and AX2 machine axes of the NCU1.
As container-link axes, the AX1 and AX2 machine axes of the NCU2.
For the axis container rotation, see Section "Programming (Page 110)".
Extended Functions
2.2 NCU link
Notes on the parameter assignment
Container axis distribution and communications utilization

In the case of a plant with several NCUs that traverse alternately axes of other NCUs (link
axes) in conjunction with axis containers, the type and manner how the link axes are
distributed within the axis container decide on the utilization of the link communication.
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Red slot: Refers to a drive connected to the NCU2
Drives connected to NCU1
Drives connected to NCU2
Figure 2-15 Axis distribution
Symmetrical axis distribution

In the case of a symmetrical axis distribution, each NCU first traverses only local axes.
This means no link communication occurs. Provided all NCUs only traverse link axes,
each transition of the axis container increases the utilization of the link communication up
to a maximum.
Asymmetrical axis distribution
For an asymmetric axis distribution, each NCU traverses local and link axes from the
beginning. Unlike the symmetrical axis distribution, this results in a "constant" average
utilization of the link communication.
Extended Functions
2.2 NCU link
Drive distribution and communications utilization

In a system with several NCUs that in conjunction with axis containers alternately traverse
axes of another NCU (link axes), the distribution of the drives connected to the NCU decides
the utilization of the link communication.
Symmetric drive distribution
In the case of a symmetric drive distribution, the drives addressed via the axis container
are connected to both NCUs. On account of this arrangement, the maximum possible
number of drives can still be addressed via the logical machine axes images (LAI) on
both NCUs.
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Asymmetric drive distribution

In the case of an asymmetric drive distribution, the drives addressed via the axis
container are only connected to NCU1. On account of this arrangement, the maximum
possible number of drives can only be addressed via the logical machine axes images
(LAI) on NCU2. Only the maximum number minus the drives used by NCU2 can be
addressed via the LAI of NCU1. In order to also be able to use the maximum number of
drives on NCU1, they must be connected to NCU2 and addressed from NCU1 via the
NCU link. This results in a higher cyclic link communication load.
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Extended Functions
2.2 NCU link
2.2.4.3 Programming
Function
The AXCTSWE or AXCTSWED commands are used to enable the rotation of the specified axis
container.
Any previously set enable for axis container rotation is cancelled with the AXCTSWEC
command.
Syntax
AXCTSWE(<ID>)
AXCTSWED(<ID>)
AXCTSWEC(<ID)
Meaning
AXCTSWE: Enable for rotation of the axis container

The program processing is not stopped by AXCTSWE.
The rotation is performed as soon as all channels involved on the axis
container have been enabled.
The increment of an axis container rotation is set via the SD41700
$SN_AXCT_SWWIDTH setting data (see Section "Parameterization
(Page 103)")
AXCTSWED: Enable to rotate the axis container without consideration of the other
channels involved on the axis container
The increment of an axis container rotation is set via the SD41700
$SN_AXCT_SWWIDTH setting data (see Section "Parameterization
(Page 103)")
Note
Command variant to simplify the commissioning of the part program or
synchronized action.
The behavior with regard to the other channels involved on the axis
container can be specified via:
MD12760 $MN_ AXCT_FUNCTION_MASK, bit 0
See Section "Parameterization (Page 103)".
AXCTSWEC: Canceling the enable to rotate the axis container
Note
The enable for rotating an axis container can only be cancelled when the
rotation has yet not been started:
$AN_AXCTSWA[<axis container>] == 0
See Section "System variable (Page 111)"
Extended Functions
2.2 NCU link
<ID>: Name of the axis container or a container axis:

CT<number>: Default identifier of an axis container:
Example: CT1
<Container>: User-specific name of an axis container:
Example: CONTAINER_1
<axis>: Name of a known container axis in the channel
References
The use of the AXCTSWEC command in synchronized actions is described in detail in:
Synchronized Actions Function Manual, Section "Detailed description" > "Actions in
synchronized actions" > "Cancel release for axis container rotation (AXCTSWEC)"
Container-specific system variable
System variable Description

$AC_AXCTSWA[<ID>] Channel-specific status of the axis container rotation
$AN_AXCTSWA[<ID>] NCU-specific status of the axis container rotation
$AN_AXCTSWE[<ID>] Slot-specific status of the axis container rotation
$AN_AXCTAS[<ID>] Number of slots through which the axis container was just
switched through.
ID: Axis container name or name of a container axis
NC-specific system variable

$AN_LAI_AX_IS_AXCTAX 1) Status: LAI axis == container axis
of the machine axes in the logical machine axis
image (MD10002
$MN_AXCONF_LOGIC_MACHAX_TAB) regarding
axis container.
$AN_LAI_AX_IS_LEADLINKAX 1) Status: LAI axis == lead-link axis
$AN_LAI_AX_IS_LINKAX 1) Status: LAI axis == link axis
$AN_LAI_AX_TO_IPO_NC_CHANAX[<ID>] Channel and channel axis number or NCU-ID and
the global axis number
$AN_LAI_AX_TO_MACHAX[<ID>] NCU-ID and axis number of the machine axis
1) Bit mask: Bit n LAI axis (n+1) from MD10002 $MN_AXCONF_LOGIC_MACHAX_TAB
ID: LAI axis number
NCU-ID: Value from MD12510 $MN_NCU_LINKNO
Extended Functions
2.2 NCU link
References
A detailed description of the system variables can be found in:
System Variables, List Manual
See also
Evaluating axis container system variables (Page 124)
2.2.4.5 Machining with axis container (schematic)
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Extended Functions
2.2 NCU link
2.2.4.6 Behavior in different operating states
Startup (Power On)

In the startup the controller, with regard to the slot assignment, the initial state defined in the
machine data is always assumed irrespective in which state of the axis container the control
was switched off:
MD1270x $MN_AXCT_AXCONF_ASSIGN_TABx
Note
Alignment between setpoint and actual status
After a controller startup, it is the sole responsibility of the user / machine manufacturer to
detect any difference between the status of the axis container and the machine status and to
compensate for this with a suitable axis container rotation.
Mode change
A container axis whose axis container in the Automatic mode was enabled for rotation
cannot be traversed after a change in the JOG mode.
Channel-specific Reset state

As soon as a channel involved on the axis container is in the Reset state, no enable for axis
container rotation is required for this channel. It suffices to enable the remaining active
channels.
Block search
An axis container rotation (AXCTSWE) cannot be enabled and activated in one block, but the
enabling and activation commands must be programmed in separate action blocks. In other
words, the axis container status changes in response to each separate rotation command as
a function of the status of other channels.
2.2.4.7 Behavior when withdrawing the release for axis container rotation
TheAXCTSWE command enables the channel-specific axis container rotation for an axis
container. The AXCTSWEC command cancels the enable.
The following figure shows an example the sequence of an axis container rotation as
represented in the axis container-specific system variables. Two channels for two NCUs are
always involved on the axis container.
Extended Functions
2.2 NCU link
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NCU1, channel1: Enable issued using the AXCTSWE command

NCU2, channel2: Enable issued using the AXCTSWE command
NCU1, channel2: Enable issued via AXCTSWE command all enables of all channels are now
present in the NCU1 the overall enable status of NCU1 is transferred to NCU2 via link
communication
NCU2, channel1: Enable issued via AXCTSWE command all enables of all channels are now
present in the NCU2 the overall enable status of NCU2 is transferred to NCU1 via link
communication
All enable signals for all channels (NCU2 and NCU1) are now present in NCU2 the axis
container rotation is performed in NCU2
NCU1: All enable signals for all channels (NCU1 and NCU2) are now present in NCU1 the
axis container rotation is performed in NCU1
NCU1/NCU2: axis container rotation has been completed
Figure 2-19 Cross-NCU enable and axis container rotation
Extended Functions
2.2 NCU link
To allow a previously granted enable to be canceled, the enable for at least one of the
channels (NCU1 or NCU2) involved on the axis container must still be pending at the time of
the cancellation. This means the cancel must be made before time .
Withdrawal is no longer possible as soon as all enable signals are available from all
channels of all NCUs (instant in time ). In this case, the AXCTSWEC command has no effect.
No feedback is sent to the user.
See also
Programming (Page 110)
Axis mode
If a container axis in axis mode or as a positioning spindle (POSA, SPOSA) traverses, the
axis container rotates only after reaching the programmed end position.
Spindle
A container axis active as a spindle continues to rotate during an axis container rotation.
The control type of a spindle (speed / position control) refers to the associated machine
axis. The set control type "moves" with the machine axis when an axis container rotates.
For commands that refer to the master spindle of the channel, a machine axis with the
corresponding spindle number must exist in the channel at the time of execution of the
command:
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ <axis>] == number of the master spindle
Note
It is the sole responsibility of the user / machine manufacturer to ensure for spindles as
container axes that an appropriate machine axis must still exist in the channel after an
axis container rotation for the master spindle.
Work offsets
Note
It is the sole responsibility of the user / machine manufacturer to ensure that after an axis
container rotation the effective work offsets in the channel are adapted to the changed
machine axis assignments.
Extended Functions
2.2 NCU link
Continuous-path mode
If continuous-path mode is active in the channel and an axis container rotation is performed,
a subsequent programming of a container axis interrupts the continuous-path mode. The
interruption also occurs even when the container axis not a path axis.
PLC axis
If a container axis whose axis container has been enabled for rotation becomes a PLC axis,
the status change occurs only after completion of the axis container rotation.
Command axis
If a container axis whose axis container has been enabled for rotation traverses as a
command axis, the traversing movement is performed only after completion of the axis
container rotation.
Oscillating axis
If a container axis whose axis container has been enabled for rotation becomes an
oscillation axis, the status change occurs only after completion of the axis container rotation.
External work offset

The "external work offset" is based on the machine coordinate system (MCS). Therefore, for
an active "external work offset", one of the container axes rejects the axis container rotation
with alarm 4022.
Axial frames
The axial frame of a channel axis, which is also a container axis, is no longer valid after an
axis container rotation. Since the axis container rotation assigns a new machine axis to the
channel axis, but the axial frame is referred to a machine axis, the rotation also changes the
axial frame. If the two frames do not coincide, a synchronization process (internal REORG)
is performed.
Note
The assignment between a channel axis and a machine axis is altered by the axis container
rotation. The current frames remain unchanged after a rotation. The user is responsible for
ensuring that the correct frames are selected after a rotation by programming basic frame
masks, for example.
Extended Functions
2.2 NCU link
Transformation
If a container axis is involved as a spindle in a transformation, the transformation must be
deselected before the enable of the axis container rotation.
Axis couplings
If an axis coupling is active for a container axis, the coupling with COUPOF must be deselected
before the enable of the axis container rotation. After completion of the rotation, the coupling
can be immediately selected again with COUPON. A new define of the coupling is not required.
Gantry axis
A gantry axis cannot be a container axis.
Travel to fixed limit

If a container axis is at the limit stop, no axis container rotation can be performed.
Drive alarms
If a drive alarm is pending for a container axis, the axis container rotation is not performed.
Extended Functions
2.2 NCU link
2.2.5 Lead link axes

If, for an axis coupling, the the machine axes of the leading and following axes are not
connected to the same NCU, the coupling must be established using a link axis of the NCU
of the following axis. In this case, the link axis is designated as lead-link axis.
The setpoints of the master axis are transferred synchronously in the interpolator cycle via
the NCU link to the lead-link axis. Similarly, in the opposite direction, the actual values and
the status data of the lead-link and the following axis are transferred to the leading axis.
The lead-link axis is parameterized as local leading axis of the following axis.
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Figure 2-20 Lead-link axis
Coupled axes
Lead link axes can be used in conjunction with following axis couplings:
Master value coupling
Coupled motion
Tangential tracking
Electronic gear (ELG)
Synchronous spindle
Requirement
The NCU must communicate via the NCU link. See Section "Link communication (Page 79)"
Extended Functions
2.2 NCU link
Link communication

MD12510 NCU_LINKNO Unique numerical identification of the NCU within the link group. The
identifiers must be assigned without any gaps in ascending ordering
starting from 1.
Value range: 1, 2, ... Maximum NCU number
Note:
The NCU to which the value 1 is assigned as NCU identification is the
master NCU of the link group. The parameterization of link axes and
axis containers may only be made with the machine and setting data of
the master NCU.
MD18780 MM_NCU_LINK_MASK.Bit 0 Activation of the link communication
MD18781 NCU_LINK_CONNECTIONS Number of internal link connections
Note:
It is recommended to retain the default value 0 (determination of the
number by the NC).
MD18782 MM_LINK_NUM_OF_MODULES Number of NCUs to be connected with one another via NCU link.
Setpoint synchronization

MD18720 MM_SERVO_FIFO_SIZE Size of the IPO/SERVO data buffer
The transfer of the setpoints of the leading axis via the NCU link to the
NCU of the lead-link axis produces a deadtime of two interpolator
cycles. The dead time is compensated by parameterizing the sizes of
the IPO/SERVO data buffer on the NCU of the leading axis and the
NCU of the lead-link axis:
NCU of the leading axis: 4
NCU of the lead-link axis: 2
Note
With the simultaneous use of lead link axes and cross-NCU axis containers, the axis
container means machine data MD18720 $MN_MM_SERVO_FIFO_SIZE = 3 must be set.
This means a synchronous output of the setpoints for leading and following axis is not
possible. The offset then has the size of one interpolator cycle.
Extended Functions
2.2 NCU link
Leading, lead-link and following axis

MD10000 AXCONF_MACHAX_NAME_TAB Machine axis name
MD10002 AXCONF_LOGIC_MACHAX_TAB Logical machine axis image
Channel-specific machine data
Number Identifier $MC_ Meaning

MD20070 AXCONF_MACHAX_USED Used machine axis
Axis-specific machine data
Number Identifier $MA_ Meaning

MD30554 AXCONF_ASSIGN_MASTER_NCU Master NCU
If a machine axis can be traversed for several NCUs, one NCU must
be defined as master NCU. The setpoint generation is made after the
startup of the control for this NCU.
2.2.5.3 System variables to enter a leading value

Leading values can be specified on the NCU of the leading axis using the following system
variable:
Position leading value: $AA_LEAD_SP[<leading axis>]
Velocity leading value: $AA_LEAD_SV[<leading axis>]
When making a change, the values are also transferred to the NCU of the following axis per
NCU link.
Note
These system variables have a lower transfer priority than those of the link variables.
Extended Functions
2.2 NCU link

The following supplementary conditions must be observed:
The leading axis cannot be a link axis
The leading axis cannot be a container axis
The leading axis cannot be a gantry axis
The leading axis may only be replaced within its own NCU (see Section "Axis/spindle
replacement (Page 320)")
Couplings with lead link axes must not be cascaded
A lead link axis must not be traversed independently of the leading axis
Note
"Lead link axes and "link axes" functions
Because the "lead link axes and "link axes" functions require different settings in machine
data: MD18720 $MN_MM_SERVO_FIFO_SIZE, they cannot be used simultaneously
within a link group.
2.2.5.5 Example
A detailed example for parameterizing and programming an axis coupling with lead-link axis
is provided in the Section: "Examples" > "Lead link axis (Page 135)".
2.2.6 System of units within a link group

For a cross-NCU interpolation, the same system of units must be active on all NCUs of the
link group.
Common system of units changeover via HMI

The following conditions must be fulfilled for all NCUs of the link group in order that a system
of units changeover can be made from the HMI user interface of an NCU of the link group as
well as on all other NCUs of the link group:
MD10260 $MN_CONVERT_SCALING_SYSTEM = 1
For all channels:
MD20110 $MC_RESET_MODE_MASK, Bit 0 = 1
All channels are in the reset state
No axis is traversed in the JOG or DRF mode or via the PLC
The function "constant grinding wheel peripheral speed (GWPS)" is not active.
If, on one NCU of the link group, one of the specified conditions is not fulfilled, then the
system of units changeover is not made on any of the NCUs of the link group.
Extended Functions
2.3 Examples
Different systems of units

Different systems of units are possible in spite of an active link group, as long as no cross
NCU interpolation takes place. The system of units settings are made for a specific NCU in
the part program or synchronous action using G commands (G70, G71, G700, G710).
References
Function Manual, Basic Functions; Velocities, Setpoint-Actual Value Systems, Closed-Loop
Control (G2)
2.3 Examples
2.3.1 Link axis
Parameter example for two NCUs each with a link axis
NCU1
Machine data Note

General link data:
$MN_NCU_LINKNO = 1 Master NCU
$MN_MM_NCU_LINK_MASK = 1 Set NCU-link active
$MN_MM_SERVO_FIFO_SIZE = 3 Size of the data buffer between interpolation and position
control
$MN_MM_LINK_NUM_OF_MODULES = 2 Number of link modules
Logical machine axis image (LAI):
$MN_AXCONF_LOGIC_MACHAX_TAB[0] = "AX1" Local machine axis
$MN_AXCONF_LOGIC_MACHAX_TAB[2] = "NC2_AX3" Link axis
Machine axis name, unique system-wide as NCU identifier:
$MN_AXCONF_MACHAX_NAME_TAB[0] = "NC1_A1"
Assignment of channel axis to machine axis:
$MC_AXCONF_MACHAX_USED[0] = 1 1. Channel axis to the machine axis of LAI[0]
$MC_AXCONF_MACHAX_USED[2]=3 3. Channel axis to the machine axis of LAI[2]
Extended Functions
2.3 Examples
NCU2
Machine data Note

General link data:
$MN_NCU_LINKNO = 2 Slave NCU
$MN_MM_NCU_LINK_MASK = 1 Set NCU-link active
control
$MN_MM_LINK_NUM_OF_MODULES = 2 Number of link modules
Logical machine axis image (LAI):
$MN_AXCONF_LOGIC_MACHAX_TAB[2] = "NC1_AX3" Link axis
Machine axis name, unique system-wide as NCU identifier:
Assignment of channel axis to machine axis:
$MC_AXCONF_MACHAX_USED[2]=3 3. Channel axis to the machine axis of LAI[2]
2.3.2 Axis container coordination

The characteristic as a function of time is displayed from top to bottom in the following
tables. The data are valid on condition that only two channels have axes in the container.
2.3.2.1 Axis container rotation without a part program wait
Channel 1 Channel 2 Comment

AXCTWE(C1) Part program ... Channel 1 enables the axis container
for rotation.
Part program without movement of a Part program ...
container axis
AXCTSWE(C1) Channel 2 enables the axis container
for rotation, container rotates because
both channels have enabled rotation
Part program with movement of a Part program with movement of a Without wait
container axis container axis
Extended Functions
2.3 Examples
2.3.2.2 Axis container rotation with an implicit part program wait

AXCTWE(C1) Part program ... Channel 1 enables the axis container
for rotation.
Part program with movement of a Part program ... Channel 1 waits implicitly for axis
container axis container rotation
AXCTSWE(C1) Channel 2 enables the axis container
for rotation, rotation occurs.
Channel 1 is continued.
2.3.2.3 Axis container rotation by one channel only (e.g. during power up)

AXCTWED(C1) In the RESET state Instantaneous rotation
2.3.3 Evaluating axis container system variables
2.3.3.1 Conditional branch
Channel 1 Comment
N100 AXCTWE(CT1) Channel 1: Enable of the rotation of axis container CT1
MARKER1:
N200 ... Part program without movement of a container axis
IF $AC_AXCTSWA[CT1] == 1 GOTOB MARKE1 IF rotation of axis container CT1 still active
THEN continue with MARKER1
ELSE (rotation of axis container CT1 completed)
N300 ... Part program with movement of a container axis
2.3.3.2 Static synchronized action with $AN_AXCTSWA
Channel 1 Comment
IDS =1 EVERY $AN_AXCTSWA[CT1] == 1 DO M99 Static synchronized action:
Always output auxiliary function M99 at the beginning of an
axis container rotation.
References: Synchronized Actions Function Manual
Extended Functions
2.3 Examples
2.3.3.3 Wait for certain completion of axis container rotation

If you want to wait until the axis container rotation is reliably completed, you can use one of
the examples below selected to suit the relevant situation.
Example 1
rl = $AN_AXCTAS[ctl]; Read current axis container position
AXCTSWE(ctl) ; Permit axis container rotation
WHILE (rl == $AN_AXCTAS[ctl]); Wait until axis container position
ENDWHILE ; has changed
Example 2 for 1st channel

CLEARM(9); Delete synchronization marker 9
AXCTSWE(ctl) ; Permit axis container rotation
; wait with synchronized action until
; axis container rotation is completed
WHEN $AN_AXCTSWA[ctl] == TRUE DO SETM(9) ; Set marker 9 and
WAITMC(9, 1) ; Wait for synchronization marker 9
; in first channel
Example 3.1 Use internal wait

M3 S100 ; Reprogram axis container spindle
; An internal wait takes place for the end of
; axis container rotation

x=IC(0) ; Reprogram axis container axis x
; An internal wait takes place for the end of
; axis container rotation
Extended Functions
2.3 Examples

AXCTSWE(CTL) ; If an axis container is reenabled for rotation,
; an internal wait takes place for the end of the earlier
; axis container rotation.
N2150 WHILE (rl == $AN_AXCTAS[ctl])
Note
Programming in the NC program:
WHILE ($AN_AXCTSWA[n] == 0)
ENDWHILE
cannot be used as a reliable method of determining whether an earlier axis container rotation
has finished. Although in software version 7.x and later, $AN_AXCTSWA performs an
implicit preprocessing stop, this type of programming cannot be used, as the block can be
interrupted by a reorganization. The system variable then returns "0" as the axis container
rotation is then ended.
2.3.4 Configuration of a multi-spindle turning machine
Introduction
The following example describes the use of:
Several NCUs in the NCU link group
Flexible configuration with axis containers
Machine description
Distributed on the circumference of a drum A (front-plane machining) the machine has:
4 main spindles, HS1 to HS4
Each main spindle has the possibility of material feed (bars, hydraulic bar feed, axes:
STN1 - STN4).
4 cross slides
Each slide has two axes.
Optionally a powered tool S1-S4 can operate on each slide.
Extended Functions
2.3 Examples
Distributed on the circumference of a drum B (rear-plane machining) the machine has:

4 counterspindles GS1 to GS4
4 cross slides
Each slide has two axes.
Optionally a powered tool S5-S8 can operate on each slide.
The position of each counterspindle can be offset through a linear axis for example for
transferring parts from the main spindle for rear-plane machining in drum B. (Transfer
axes. Axes: ZG1 - ZG4).
Couplings:
If drum A rotates, all main spindles of this drum are subordinate to another group of
slides.
If drum B rotates, all main counterspindles and all transfer axes of this drum are
subordinate to another group of slides.
The rotations of drums A and B are autonomous.
The rotations of drums A and B are limited to 270 degrees.
(range and twisting of supply cables)
Term: Position
Main spindle HSi and counterspindle GSi together with their slides characterize a position.
NCU assignment
The axes and spindles of a position (for this example) are each assigned to an NCU. One of
the NCUs, the master NCU, controls the axes for the rotations of drums A and B additionally.
There are 4 NCUs with a maximum of the following axes:
Number of axes
Per NCUi the following axes/spindles must be configured:
Slide 1: Xi1, Zi1
2: Xi2, Zi2
Spindles: HSi, GSi, powered tools: S1, S2
Transfer axis: ZGi
Bar feed: STNi.
For the master NCU, in addition to the above-mentioned axes there are the two axes for
rotating drums A and B. The list shows that it would not be possible to configure the axis
number for a total of 4 positions via an NCU. (Limit 31 axes, required are 4 + 10 + 2 axes).
Extended Functions
2.3 Examples
Axis container
With rotation of drums A/B, HSi, GSi, ZGi and STNi must be assigned to another NCU and
must therefore be configured as link axes in axis containers.
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Figure 2-21 Schematic diagram of main spindles HSi, countersp. GSi, bar feed axis STNi and transfer axes ZGi
Extended Functions
2.3 Examples
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Figure 2-22 Two slides per position can also operate together on one spindle.
Note
The axes are given the following names in order to clarify the assignments of axes to slides
and positions:
Xij with i slide (1, 2), j position (A-D)
Zij with i slide (1, 2), j position (A-D)
Whereas the positions and their slides remain in one place, main spindles, counterspindles,
bar feed axes STN and transfer axes ZG move to new positions as the result of rotations of
drums V or H.
For example, the axes to be managed per NC when the slide is taken into account are as
follows for the configurations shown in the above diagrams:
Extended Functions
2.3 Examples
Axes of master NCU

Table 2- 1 Axes of master NCU: NCUa
Common axes Local axes Comment

TRV (drum V) Master NCU only
TRH (drum H) Master NCU only
X1A Slide 1
Z1A Slide 1
X2A Slide 2
Z2A Slide 2
S1 Slide 1
S2 Slide 2
HS1 Axis container necessary
GS1 Axis container necessary
ZG1 Axis container necessary
STN1 Axis container necessary
4 8
Axes of NCUb to NCUd

The NCUs that are not master NCUs have the same axes with the exception of the axes for
the drive for drums TRV and TRH. The letter designating the position must be replaced
accordingly for the NCU and axis name (a, A b, B to d, D).
Configuration rules
The following rules were applied for the configuration described below:
Main spindle, counterspindles and axes that are assigned to different NCUs through drum
rotation while they are operating as illustrated in the above diagram "Main spindle ..."
must be configured in an axis container.
(HSi, GSi, ZGi, STNi).
All main spindles for drum A are in the same container (No. 1).
All bar feed axes for drum A are in the same container (No. 2).
All counterspindles for drum B are in the same container (No. 3).
All transfer axes for drum B are in the same container (No. 4).
Main spindles HSi and their counterspindle GSi as well as the transfer axes for
counterspindle ZGi and the bar feed axes STNi of the main spindle are assigned as
follows for uniform load distribution purposes:
NCUa HS1-STN1,
NCUb HS2-STN2, ... etc.
Slide axes Xij, Zij are solely local axes with a fixed NCU assignment.
Slides are assigned to a dedicated channel of an NCU.
Slides can therefore be moved autonomously.
Extended Functions
2.3 Examples
Configuration options
Main or counterspindles are flexibly assigned to the slide.
The speed of the main spindle and the counterspindle can be defined independently in
each position.
Exceptions:
During the parts change from front-plane machining in drum V to rear-plane machining in
drum H, the speeds of the main spindle and the counterspindle must be synchronized
(synchronous spindle coupling).
In cases where slide 2 also participates in front-plane machining so as to "support" slide
1, the main spindle speed also applies to slide 2. Similarly if slide 1 participates in rear-
plane machining, the counterspindle speed also applies to slide 1.
Minor changes in speed

Due to the unavoidable time delays incurred in the processing of actual values, abrupt
changes in speed should be avoided during cross-NCU machining operations. Compare axis
data and signals.
Configuration for NCU1

Uniform use of channel axis names in the part programs:
S4: Main spindle
S3: Counterspindle
X1: Infeed axis
Z1: Longitudinal axis
S1: Powered tool
Z3: Transfer axis
TRV: Drum V for main spindle
TRH: Drum H for counterspindle
STN: Hydraulic bar feed
Axes highlighted in bold characterize the current channel as home channel for the axis in
conjunction with axis replacement.
Extended Functions
2.3 Examples
Table 2- 2 NCUa, position: a, channel: 1, slide: 1
Channel axis name ..._MACHAX $MN_ Container, slot Machine axis name
_USED AXCONF_LOGIC_MACH entry (string)
AX_TAB,
S4 1 AX1: CT1_SL1 11 HS1
NC1_AX1
S3 2 AX2: CT3_SL1 31 GS1
NC1_AX2
X1 3 AX3: X1A
Z1 4 AX4: Z1A
Z3 5 AX5: CT4_SL1 41 ZG1
NC1_AX5
S1 6 AX6: WZ1A
STN 7 AX7: CT2_SL1 21 STN1
NC1_AX7
TRV 11 AX11: TRV
TRH 12 AX12: TRH
x2 *
z2 *
Table 2- 3 NCUa, position: a, channel: 2, slide: 2
Channel axis name ..._MACHAX $MN_ Container, slot Machine axis name
_USED AXCONF_LOGIC_MACH entry (string)
AX_TAB,
S4 1 AX1: CT1_SL1 11 HS1
NC1_AX1
S3 2 AX2: CT3_SL1 31 GS1
NC1_AX2
Z3 5 AX5: CT4_SL1 41 ZG1
NC1_AX5
STN 7 AX7: CT2_SL1 21 STN1
NC1_AX7
X2 8 AX8: X2A
Z2 9 AX9: Z2A
S1 10 AX10: WZ2A
x1 *
z1 *
Note
* due to program coordination via axis positions and 4-axis machining in one position
Entries in the axis container locations should have the following format: "NC1_AX.." with the
meaning NC1 = NCU 1. In the above tables, NCUa is imaged on NC1_..., NCUb on NC2_...
etc.
Extended Functions
2.3 Examples
Further NCUs
The above listed configuration data must be specified accordingly for NCUb to NCUd.
Please note the following:
Axes TRA and TRB only exist for NCUa, channel 1.
The container numbers are maintained for the other NCUs as they were specified for the
individual axes
The slot numbers are as follows:
NCUb 2
NCUc 3
NCUd 4.
The machine axis names are as follows:
NCUb HS2, GS2, ZG2, STN2
NCUc HS3, GS3, ZG3, STN3
NCUd HS4, GS4, ZG4, STN4.
Axis container
The information relating to containers given in Table 7-17 and the container entries of the
similarly configured NCUs, NCUb to NCUd, are specified in the following tables, sorted
according to containers and slots, as they have to be set in machine data:
MD12701 $MN_AXCT_AXCONF_ASSIGN_TAB1[slot]
...
MD12716 $MN_AXCT_AXCONF_ASSIGN_TAB16[slot]
whereby slots: 1-4 must be set for the 4 positions of a multi-spindle turning machine:
Note
For the machine data entry
$MN_AXC_AXCONF_ASSIGN_TABi[slot]
the values (without decimal point and machine axis name) that are entered under initial
position in the above tables must be set.
Extended Functions
2.3 Examples
Table 2- 4 Axis container and their position-dependent contents for drum A
Container Slot Initial position Switch 1 Switch 2 Switch 3 Switch 4 =

(TRA 0) (TRA 90) (TRA 180) (TRA 270) (TRA 0)
1 1 NC1_AX1, HS1 NC2_AX1, HS2 NC3_AX1, HS3 NC4_AX1, HS4 NC1_AX1, HS1
2 NC2_AX1, HS2 NC3_AX1, HS3 N4C_AX1, HS4 NC1_AX1, HS1 NC2_AX1, HS2
3 NC3_AX1, HS3 NC4_AX1, HS4 NC1_AX1, HS1 NC2_AX1, HS2 NC3_AX1, HS3
4 NC4_AX1, HS4 NC1_AX1, HS1 NC2_AX1, HS2 NC3_AX1, HS3 NC4_AX1, HS4
2 1 NC1_AX7, STN1 NC2_AX7, STN2 NC3_AX7, STN3 NC4_AX7 STN4 NC1_AX7, STN1
2 NC2_AX7, STN2 NC3_AX7, STN3 NC4_AX7, STN4 NC1_AX7, STN1 NC2_AX7, STN2
Drum movement 0 + 90 + 90 + 90 - 270
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Figure 2-23 Positions of drum A
Table 2- 5 Axis container and their position-dependent contents for drum B
Container Slot Initial position Switch 1 Switch 2 Switch 3 Switch 4 =

(TRB 0) (TRB 90) (TRB 180) (TRB 270) (TRB 0)
3 1 NC1_AX2, GS1 NC2_AX2, GS2 NC3_AX2, GS3 NC4_AX2, GS4 NC1_AX2, GS1
2 NC2_AX2, GS2 NC3_AX2, GS3 NC4_AX2, GS4 NC1_AX2, GS1 NC2_AX2, GS2
4 1 NC1_AX5, ZG1 NC2_AX5, ZG2 NC3_AX5, ZG3 NC4_AX5 ZG4 NC1_AX5, ZG1
2 NC2_AX5, ZG2 NC3_AX5, ZG3 NC4_AX5, ZG4 NC1_AX5, ZG1 NC2_AX5, ZG2
Extended Functions
2.3 Examples
2.3.5 Lead link axis
2.3.5.1 Configuration
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Figure 2-24 NCU2 to NCUn use a lead link axis to enable coupling to the machine axis on NCU1 (NCU1-AX3).
The following example refers to the axis coupling section between Y(LAX2, AX2) as
following axis on NCU2 and Z(LAX3, NC1_AX3) as lead link axis.
Machine data
The machine data of a leading value axis may only be loaded on the home NCU. From
this NCU, the relevant machine data are distributed to the other NCUs where a lead link
axis has been defined.
Each lead link axis reduces the maximum number of axes that can be traversed on this
NCU by one axis.
Extended Functions
2.3 Examples
Machine data for NCU1 (leading axis)
Machine data Meaning

$MN_NCU_LINKNO = 1 1. or master NCU
$MN_MM_NCU_LINK_MASK = 1 NCU link active
$MN_MM_LINK_NUM_OF_MODULES= 2 Number of link modules
$MN_MM_SERVO_FIFO_SIZE = 4 The size of the data buffer is increased to 4 between
interpolation and position control
$MN_AXCONF_LOGIC_MACHAX_TAB[0] = "AX1"
$MN_AXCONF_MACHAX_NAME_TAB[0] = "XM1"
$MN_AXCONF_MACHAX_NAME_TAB[2] = "YM1"
$MA_AXCONF_ASSIGN_MASTER_NCK[ AX3 ] = 1
$MC_AXCONF_MACHAX_USED[0]=1 ; X
$MC_AXCONF_MACHAX_USED[1]=2 ; Y
$MC_AXCONF_MACHAX_USED[2]=3 ; Z
Machine data for NCU2 (following axis)

$MN_NCU_LINKNO = 2 2. NCU number
$MN_MM_NCU_LINK_MASK = 1 Activate link
$MN_MM_NUM_CURVE_TABS = 5 Number of curve tables
$MN_MM_LINK_NUM_OF_MODULES= 2 Number of link modules
$MN_MM_NUM_CURVE_SEGMENTS= 50
$MN_MM_NUM_CURVE_POLYNOMS = 100
control (standard)
$MN_AXCONF_LOGIC_MACHAX_TAB[0] = "NC1_AX3" Lead link on NCU1/AX3
$MC_AXCONF_MACHAX_USED[0]=3 AX3 is machine axis of the 1st channel axis

$MC_AXCONF_MACHAX_USED[1]=2 AX2 is machine axis of the 2nd channel axis
$MC_AXCONF_MACHAX_USED[2]=1 AX3 on NCU1 is machine axis of the 3rd channel axis
Extended Functions
2.3 Examples
2.3.5.2 Programming
Program for NCU1 (leading axis)

NCU1 traverses leading axis Z
Identifier for NCU2, that the leading axis of NCU1 is assigned: Link variable $A_DLB[0] = 1
Identifier for NCU2, that the leading axis of NCU1 has been released: Link variable
$A_DLB[0] = 0

N1000 R1 = 0 ; Initialize loop counter
N1004 G1 Z0 F1000 ; Traverse axis Z to the starting position
N1005 $A_DLB[0] = 1 ; Identifier for NCU2: Axis Z is assigned
LOOP10: ;
N1005 R1=R1+1 ; Increment loop counter
N1006 Z0.01 G91 ; Traversing the leading value axis Z
N1008 Z0.02 ; Traversing the leading value axis Z
N1010 Z0.03 ; Traversing the leading value axis Z
N1012 IF R1 < 10 GOTOB LOOP10 ;
N1098 $A_DLB[0] = 0 ; Identifier for NCU2: Axis Z is free
Program for NCU2 (following axis)

The program establishes a connection between leading axis movements on NCU1 and
following axis movements on NCU2 via a curve table. If the table has been defined, NCU2
goes into the wait position (N2006) until NCU1 has assigned axis Z as the leading axis
(N1005). The coupling is activated (N2010) as soon as axis Z has been assigned as leading
axis. The coupling is kept until NCU1 has released axis Z as the leading axis.

N2000 CTABDEL(1) ; Initialize table 1
N2001 G04 F.1 ;
N2003 G0 Y0 Z0 ; Traverse axes Y, Z into the starting position
N2002 CTABDEF(Y, Z, 1, 0) ; Table definition ON
N2003 G1 X0 Y0 ; Intermediate point 1
N2004 G1 X100 Y200 ; Intermediate point 2
N2005 CTABEND ; Table definition OFF
LOOP20: ;
N2006 IF ($A_DLB[0] == 0) GOTOB LOOP20 ; Wait for NCU1
N2010 LEADON(Y,Z,1) ; => close coupling
LOOP25: ;
N2030 IF ($A_DLB[0] > 0) GOTOB LOOP25 ; Keep the coupling until NCU1 no longer
traverses the leading value axis
N2090 LEADOF(Y,Z) ; => open coupling
Extended Functions
2.4 Data lists
2.4 Data lists
2.4.1 Machine data

10002 AXCONF_LOGIC_MACHAX_TAB Logical NCU machine axis image
10065 POSCTRL_DESVAL_DELAY Position setpoint delay
10134 MM_NUM_MMC_UNITS Number of simultaneous MMC communication
partners
12510 NCU_LINKNO NCU number in an NCU group
12520 LINK_TERMINATION NCU numbers for which bus terminating resistors are
active
12530 LINK_NUM_OF_MODULES Number of link modules
12701 AXCT_AXCONF_ASSIGN_TAB1 List of axes in the axis container
... ...
12716 AXCT_AXCONF_ASSIGN_TAB16
12750 AXCT_NAME_TAB List of axis container names
12760 AXCT_FUNCTION_MASK Functions for the axis container
18700 MM_SIZEOF_LINKVAR_DATA Size of the link variables memory
18720 MM_SERVO_FIFO_SIZE Size of the data buffer between interpolation and
position controller
18780 MM_NCU_LINK_MASK, bit 0 Link communication activation

20000 CHAN_NAME Channel name
20070 AXCONF_MACHAX_USED Machine axis number valid in channel
28160 MM_NUM_LINKVAR_ELEMENTS Number of write elements for the NCU link variables
Extended Functions
2.4 Data lists
2.4.1.3 Axis/spindlespecific machine data
Number Identifier: $MA_ Description

30550 AXCONF_ASSIGN_MASTER_CHAN Default assignment between an axis and a channel
30554 AXCONF_ASSIGN_MASTER_NCU Initial setting defining which NCU generates setpoints
for the axis
30560 IS_LOCAL_LINK_AXIS Axis is a local link axis
32990 POCTRL_DESVAL_DELAY_INFO Current position setpoint delay
2.4.2 Setting data
Number Identifier: $SA Description

41700 AXCT_SWWIDTH[container number] Axis container rotation setting
2.4.2.2 Axis/spindle-specific setting data
Number Identifier: $SA_ Description

43300 ASSIGN_FEED_PER_REV_SOURCE Rotational feedrate for positioning axes/spindles
2.4.3 Signals
Signal name SINUMERIK 840D sl

MCP1 ready DB10.DBX104.0
MCP2 ready DB10.DBX104.1
HHU ready DB10.DBX104.2
NCU link active DB10.DBX107.6
HMI2-CPU ready (HMI connected to OPI or MPI) DB10.DBX108.1
HMI1-CPU at MPI ready DB10.DBX108.2
HMI1-CPU at OPI ready (standard connection) DB10.DBX108.3
Extended Functions
2.4 Data lists
2.4.3.2 Signals from HMI/PLC

ONL_REQUEST DB19.DBB100
Online request from HMI
ONL_CONFIRM DB19.DBB102
Acknowledgement from PLC for online request
PAR_CLIENT_IDENT DB19.DBB104
HMI writes its client identification (bus type, HMI bus
address)
PAR_MMC_TYP DB19.DBB106
HMI type according to NETNAMES.INI: Main/secondary
operator panel/alarm server
PAR_MSTT_ADR DB19.DBB107
HMI writes address to the MCP to be activated
PAR_STATUS DB19.DBB108
PLC writes the online enable for the HMI (connection
state)
PAR_Z_INFO DB19.DBB109
PLC writes additional information to the connection state
M_TO_N_ALIVE DB19.DBB110
Sign of life from the PLC to HMI using M to N block
2.4.3.3 General online interface

MMC1_CLIENT_IDENT DB19.DBB120
PLC writes PAR_CLIENT_IDENT to
MMCx_CLIENT_IDENT, if HMI goes online.
MMC1_TYP DB19.DBB122
PLC writes PAR_MMC_TYP to MMCx_TYP, if HMI goes
online.
MMC1_MSTT_ADR DB19.DBB123
PLC writes PAR_MSTT_ADR to MMCx_MSTT_ADR, if
HMI goes online
MMC1_STATUS DB19.DBB124
Connection state, HMI and PLC write alternating, their
requests/acknowledgements.
MMC1_Z_INFO DB19.DBB125
Additional information, connection state (pos./neg.
acknowledgement, error messages, ...)
MMC1_SHIFT_LOCK DB19.DBX126.0
HMI switchover lock
Extended Functions
2.4 Data lists

MMC1_MSTT_SHIFT_LOCK DB19.DBX126.1
MCP switchover lock
MMC1_ACTIVE_REQ DB19.DBX126.2
HMI requests active operator mode
MMC1_ACTIVE_PERM DB19.DBX126.3
Enable from PLC to change the operator mode
MMC1_ACTIVE_CHANGED DB19.DBX126.4
HMI has changed the operator mode
MMC1_CHANGE_DENIED DB19.DBX126.5
HMI active/passive switchover denied
MMC2_CLIENT_IDENT DB19.DBB130
PLC writes PAR_CLIENT_IDENT to
MMCx_CLIENT_IDENT, if HMI goes online.
MMC2_TYP DB19.DBB132
PLC writes PAR_MMC_TYP to MMCx_TYP, if HMI goes
online.
MMC2_MSTT_ADR DB19.DBB133
PLC writes PAR_MSTT_ADR to MMCx_MSTT_ADR, if
HMI goes online.
MMC2_STATUS DB19.DBB134
Connection state, HMI and PLC write alternating, their
requests/acknowledgements.
MMC2_Z_INFO DB19.DBB135
Additional information, connection state (pos./neg.
acknowledgement, error messages, ...)
MMC2_SHIFT_LOCK DB19.DBX136.0
HMI switchover lock
MMC2_MSTT_SHIFT_LOCK DB19.DBX136.1
MCP switchover lock
MMC2_ACTIVE_REQ DB19.DBX136.2
HMI requests active operator mode
MMC2_ACTIVE_PERM DB19.DBX136.3
Enable from PLC to change the operator mode
MMC2_ACTIVE_CHANGED DB19.DBX136.4
HMI has changed the operator mode
MMC2_CHANGE_DENIED DB19.DBX136.5
HMI active/passive switchover denied
Extended Functions
2.4 Data lists
2.4.3.4 Signals from axis/spindle

NCU link axis active DB31, ... .DBX60.1 -
Axial alarm DB31, ... .DBX61.1 DB390x, DBX1.1
Axis ready DB31, ... .DBX61.2 DB390x, DBX1.2
Axis container rotation active DB31, ... .DBX62.7 -
2.4.4 System variables

$AN_AXCTSWE[axis] Supplies the slots of the axis container of the specified axis which are
enabled for the next axis container rotation
$AN_LAI_AX_IS_AXCTAX Contains the container axes of the logical machine axis image as bit field
$AN_LAI_AX_IS_LINKAX Contains the link axes of the logical machine axis image as bit field
$AN_LAI_AX_IS_LEADLINKAX Contains the lead-link axes of the logical machine axis image as bit field
$AN_LAI_AX_TO_MACHAX[axis] For the specified axis of the logical machine axis image, supplies the
NCU-ID and the axis number of the associated machine axis
$AN_LAI_AX_TO_IPO_NC_CHANAX[axis] For the specified axis of the logical machine axis image, supplies the
channel and channel axis number and/or the NCU and global axis
number
$AN_IPO_CHANAX[global axis number] For the specified global axis number, supplies the channel and channel
axis number
$AA_MACHAX[axis] For the specified axis, supplies the NCU-ID and the machine axis number
$AA_IPO_NC_CHANAX[axis] For the specified axis, supplies the channel and channel axis number or
NCU-ID and the global axis number
$VA_IPO_NC_CHANAX[axis] For the specified machine axis, supplies the channel and channel axis
number or NCU-ID and global axis number
A more detailed description of system variables can be found in

References:
System Variables List Manual
Extended Functions
H1: Manual and handwheel travel 3
3.1 Introduction
3.1.1 Overview
Even on modern, numerically controlled machine tools, a facility must be provided that
allows the user to traverse the axes manually.
Setting up the machine
This is especially necessary when a new machining program is being set up and the
machine axes have to be moved with the traversing keys on the machine control panel or
with the electronic handwheel. Where coordinate offset or rotation is selected, manual
travel can even be performed in the transformed workpiece coordinate system.
Retraction of the tool after a program abort
After a program abort due to a power failure or RESET, the operator must manually
retract the tool from its current machining position. This is usually done by operating the
traversing keys in JOG mode. The transformations and coordinate systems used for
machining must remain active while this is done.
Functions
The following functions are available to manually traverse axes:
Continuous traversing in jog or continuous mode
Incremental traversing in jog or continuous mode
Traversing of axes via electronic handwheels
Handwheel override in AUTOMATIC mode with path specification and/or velocity override
Correction of the tool wear for machining in AUTOMATIC mode by means of additional
incremental work offset using the handwheel (DRF)
Approach of fixed points specified via the machine data
Retraction movement in the tool direction after a program abort due to a power failure or
RESET
Extended Functions
H1: Manual and handwheel travel
3.1 Introduction
3.1.2 General characteristics when traversing in the JOG mode

The following is a description of the characteristics which generally apply to manual travel in
JOG mode (irrespective of the type selected).
JOG mode
Manual traversing of axes via the traversing keys of the machine control panel by the
operator, referred to as manual traversing in the following, is performed in JOG mode.
If JOG mode is active for the current mode group, this is reported to the PLC via the
corresponding interface signal:
DB11 DBX6.2 (BAG1: operating mode JOG)
...
References:
Function Manual, Basic Functions; Mode Group, Channel, Program Operation, Reset
Response (K1)
Machine functions
There are several JOG variants, the so-called machine functions, within JOG mode:
Continuous (JOG CONT)
Incremental (JOG INC)
Jogging with the handwheel
Handwheel travel
Handwheel travel is also active with the following functions:
JOG REPOS machine function for traversing the geometry and machine axes
AUTOMATIC mode for moving out a DRF offset
With path override
When moving the reversal point of an oscillation
The active machine function is selected via the PLC interface. A separate PLC interface
exists for both the machine axes (axis-specific) and the geometry axes (channel-specific).
Traversing several axes

Several axes can be traversed simultaneously in JOG mode. However, there is no
interpolatory relationship.
Extended Functions
3.1 Introduction
Velocity
The velocity for a JOG traversing movement is determined by the following value settings
depending on the feedrate mode:
Linear feedrate (G94) is active (SD41100 $SN_JOG_REV_IS_ACTIVE = 0):
With the general setting data:
SD41110 $SN_JOG_SET_VELO (axis velocity for JOG)
Or, for rotary axes with general setting data:
SD41130 $SN_JOG_ROT_AX_SET_VELO
(JOG speed for rotary axes)
Or (only if SD41110 = 0) with the axial machine data:
MD32020 $MA_JOG_VELO (conventional axis velocity)
Revolutional feedrate (G95) is active (SD41100 $SN_JOG_REV_IS_ACTIVE = 1):
With the general setting data:
SD41120 $SN_JOG_REV_SET_VELO (revolutional feedrate of axes in JOG)
Or (only if SD41120 = 0) with axial machine data:
MD32050 $MD_JOG_REV_VELO (revolutional feedrate for JOG)
The default setting for feedrate velocity is mm/min or rpm for revolutional feedrate or rotary
axes.
Note
Because of the limited feedrate, the axis is not able to follow the handwheel rotation
synchronously, especially in the case of a large pulse weighting, and therefore overtravels.
Rapid traverse override

If the traversing key is also actuated together with the rapid traverse override key, the
movement will be made with the configured rapid traverse velocity:
MD32010 $MA_JOG_VELO_RAPID (rapid traverse in jog mode)
MD32040 $MA_JOG_REV_VELO_RAPID (rapid traverse, revolutional feedrate)
Feedrate override
The traversing velocity for JOG can also be influenced using the axial feedrate override
switch provided that the following NC/PLC interface signal is set:
DB31, ... DBX1.7 (axial feedrate override active)
Percentages are assigned to the individual feedrate override switch positions via machine
data. For a switch position of 0% the axis is not traversed, provided that 0 is entered in the
associated machine data.
Extended Functions
3.1 Introduction
The interface signal DB31, ... DBX1.7 (axial feedrate override active) has no meaning for
switch position 0%.
Instead of being set by the feedrate override switch position (gray code), the percentage
value (0% to 200%) can optionally be set directly by the PLC. Again, the selection is made
via machine data.
References:
Function Manual, Basic Functions; Feedrates (V1)
Acceleration
With manual travel and handwheel travel, acceleration also takes place according to a
programmed characteristic. The acceleration characteristic effective for JOG for the
individual axis is defined, using the following axial machine data:
MD32420 $MA_ JOG_AND_POS_JERK_ENABLE (basic setting of the axial jerk limiting)
You can specify your own axial acceleration and jerk limitation values for manual travel in
JOG:
MD32301 $MA_JOG_MAX_ACCEL (maximum axial acceleration for JOG movements)
MD32436 $MA_JOG_MAX_JERK (maximum axial jerk for JOG movements)
Reference:
Function Manual, Basic Functions; Acceleration (B2)
Display
The JOG main screen appears when JOG mode is selected. This main screen contains
values relating to position, feedrate, spindle, and tool.
Coordinate systems
In JOG mode, the user has the option to traverse axes in different coordinate systems.
The following coordinate systems are available:
Basic coordinate system
Each axis can be traversed manually.
Workpiece coordinate system
Only geometry axes can be traversed manually (channel-specific).
Geometry axes
In manual travel, a distinction must be made as to whether the affected axis is to be
traversed as a machine axis (axis-specific) or as a geometry axis (channel-specific).
First we will focus on the characteristics of machine axes. Special features relating to the
manual traversal of geometry axes are described in "Manual travel of geometry/orientation
axes (Page 209)".
Extended Functions
3.1 Introduction
Spindle manual travel

Spindles can also be traversed manually in JOG mode. Essentially, the same conditions
apply as for manual travel of axes. Spindles can be traversed in JOG mode using the
traversing keys continuously or incrementally, in jog or continuous mode, or using the
handwheel. The mode is selected and activated via the axis-/spindle-specific PLC interface
as for the axes. The axis-specific machine data also applies to the spindles. Special features
relating to the manual traversal of spindles are described in "Spindle manual travel
(Page 211)".
3.1.3 Control of manual-travel functions via PLC interface

The manual traversing functions in the NC are activated via the NC/PLC interface from the
machine control panel (MCP). To do this, the input signals of the machine control panel from
the PLC must be transferred to the input interface of the NC in the NC/PLC interface. In this
way, the machine manufacturer can simply adapt the manual traversing functionality to the
machine tool through the PLC user program. You can use this, for example, to change the
assignment between the direction keys of the machine control panel and the traversing
requests to the NC with regard to the machine and geometry axes.
Basic procedure
The following figure shows the basic procedure for the selection of JOG mode from the
machine control panel (MCP) to the NC.
1&8
1& 3/&
2
%DVLF 3/& 1
3/& XVHU 0&3
SURJUDP SURJUDP
3
The operator selects, for example, the "Continuous JOG" machine function on the machine control panel for a
machine axis.
The input signals of the MCP are transferred cyclically from the basic PLC program in the data blocks of the MCP
input interface.
The PLC user program reads the input signals of the MCP. The input signals can be linked with any other signals in
accordance with the current machine or machining situation. Finally, the PLC user program writes the
corresponding request signals to the NC in the respective axial NC/PLC interface.
The basic PLC program transfers the request signals in the internal input interface to the NC.
After activation of the requested function, the NC writes the feedback in the internal output interface to the PLC. The
basic PLC program cyclically transfers the output signals in the respective axial NC/PLC interface
Extended Functions
3.2 Continuous (JOG CONT)
References
Detailed information on the configuration and integration of machine control panels in the
PLC user program can be found in the Basic Functions manual:
SINUMERIK 840D sl: "P3: Basic PLC program for SINUMERIK 840D sl"
SINUMERIK 828D: "P4: PLC for SINUMERIK 828D"
3.2.1 General functionality
Selection
Continuous mode in JOG mode must be selected via the PLC interface:
DB21, ... DBX13.6 (machine function: continuous)
Once the continuous procedure is active, the following interface signal is returned to the
PLC:
DB21, DBX41.6 (active machine function: continuous)
Traversing keys
The plus and minus traversing keys are selected to move the relevant axis in the appropriate
direction. If both traversing keys are pressed simultaneously, there is no traversing
movement, or, if an axis is in motion, it is stopped.
Note
When the control is switched on, axes can be traversed to the limits of the machine because
they have not yet been referenced. Hardware limit switches might be triggered as a result.
The software limit switches and the working-area limitation are not operative.
Traversing command plus/minus

As soon as a traverse request for an axis is active (e.g. after selection of a traverse key), one
of the following two interface signals is sent to the PLC (depending on selected traverse
direction):
DB21, ... DBX40.7 (traversing command plus)
or
DB21, DBX40.6 (traversing command minus)
Extended Functions
3.2.2 Distinction between inching mode continuous mode

Continuous traversing in jog mode can be performed in jogging or in continuous traversing.
Continuous traversing in jog mode

In jog mode, the axis traverses as long as the traversing key is pressed. With the release of
the traversing key, the axis is decelerated to standstill. The movement is completed when
the parameterized exact stop criterion of the axis is reached.
If the axis reaches a traversing range limit before the traversing key is released (working
area limitation, software limit switch, etc.), the axis is stopped at the limit.
Continuous traversing in continuous mode

In continuous mode, traversing of the axis is started by pressing the traversing key. The
traversing movement is continued even after the traversing key is released.
WARNING
Risk of collision
In continuous mode, several axes can be started by pressing the respective traversing key.
Any interlocks must be implemented by the user / machine manufacturer via the PLC user
program.
The traversing movement can be interrupted and continued by the operator at any time or
aborted. If the axis reaches a traversing range limit before canceling the traversing
movement (working area limitation, software limit switch, etc.), the axis is stopped at the
limit.
Interrupt traversing movement

The operator can interrupt traversing via the user interface of the machine control panel
(MCP) in the following ways:
Feedrate override = 0%
Feedrate stop
NC stop or NC stop axis/spindle
If the cause of the interruption is removed, the axis continues to traverse.
Extended Functions
Abort traversing movement

The operator can abort traversing via the user interface of the machine control panel (MCP)
in the following ways:
Pressing the same traversing key again
Pressing the traversing key for the opposite direction
RESET
Deselection of the JOG mode by changing the operating mode to AUTOMATIC or MDI
The traversing movement is aborted from the control when:
An active traversing range limit is reached (working area limitation, software limit switch,
etc.)
CAUTION
Traversing range limit inactive
Software limit switches and working-area limitations are only active after referencing of
the axis.
An alarm occurs with cancellation of the traversing movements
The selection of jog or continuous mode is performed NC-specifically for all axes via the
setting data:
SD41050 $SN_JOG_CONT_MODE_LEVELTRIGGRD (jog/continuous mode for JOG
continuous)
Indexing axis
An indexing axis always stops at an indexing position both in jog mode and in continuous
mode. In jog mode, the indexing axis traverses to the next indexing position in the direction
of travel, for example, when the traversing key is released (see Section "T1: Indexing axes
(Page 771)").
Extended Functions
3.3 Incremental (JOG INC)
Function
With incremental traversing, the operator specifies the number of increments to be traversed
by the axis via the machine control panel.
In addition to five fixed increment sizes (default setting: INC1, INC10, INC100, INC1000 and
INC10000), a variable increment size (INCvar) that can be set via the setting data is also
available.
Fixed increments
The parameter assignment of the fixed increment sizes is performed via NC-specific
machine data:
MD11330 $MN_JOG_INCR_SIZE_TAB[1 ... 5] = <number of increments 1 ... 5>
Variable increment
The parameter assignment of the variable increment size is performed via NC-specific
setting data:
SD41010 $SN_JOG_VAR_INCR_SIZE = <number of increments>
Distance evaluation of one increment

The distance evaluation of one increment for fixed and variable increment sizes is performed
via the axis-specific machine data:
MD31090 $MA_JOG_INCR_WEIGHT = <distance>
Note
Reversal of the direction evaluation
The input of a negative value causes a reversal of the direction evaluation of the traversing
keys or the handwheel direction of rotation.
NC/PLC interface
Selection, axial
DB31, ... DBX5.0 - 5.5 (machine function: INC1 to INCvar)
Feedback, axial
DB31, ... DBX65.0 - 65.5 (active machine function: INC1 to INCvar)
Extended Functions
3.3.2 Distinction between jogging mode and continuous mode

Analogous to the continuous traversing in JOG mode, incremental traversing can also be
performed in jogging or in continuous traversing.
Incremental travel in jogging mode
Function
If the traversing key for the required direction (e.g. +) is pressed, the axis begins to traverse
the increment that has been set. If the traversing key is released before the increment has
been fully traversed, the movement is interrupted and the axis stops. If the same traversing
key is pressed again, the axis traverses the remaining distance until it is zero. Up to this
point, the movement can still be interrupted by releasing the traversing key.
Pressing the traversing key for the opposite direction does not have any effect, unless the
increment has been fully traversed or the movement has been aborted.

If the increment should not travel to the end, the traversing movement can be interrupted as
follows:
RESET
DB31, ... DBX2.2 (delete distance-to-go)
Incremental travel in continuous mode
Function
The axis traverses the entire set increment when the traversing key is pressed (first rising
edge). If the same traversing key is pressed again (second rising edge) before the axis has
finished traversing the increment, the traversing movement is aborted, i.e. not completed.
Interrupt traversing movement

Behavior as for continuous travel.

The traversing movement can be stopped and aborted by means of the following operations
or monitoring functions:
Pressing the same traversing key again
Pressing the traversing key for the opposite direction
RESET
Extended Functions
When the first valid limit is reached
CAUTION
Traversing range limit inactive
Software limit switches and working-area limitations are only activated after reference
point approach.
Deselection or change of the current increment (e.g. change from INC100 to INC10)
When faults occur (e.g. on cancellation of the servo enable)
WARNING
Risk of collision
If "continuous" mode is selected, several axes can by started by pressing and releasing the
relevant direction key. Any interlocks must be implemented via the PLC!
Note
While an axis is moving, a change of mode from JOG to AUTOMATIC or MDI is not
permitted within the control.
The selection of jog or continuous mode is performed NC-specifically for all axes via the
machine data:
MD11300 $MN_JOG_INC_MODE_LEVELTRIGGRD (INC and REF in jog mode)
Jogging mode is the default setting.
Indexing axis
Irrespective of the set increment value, an indexing axis traverses to the next indexing
position in the direction of travel after pressing the traversing key (see Section "T1: Indexing
axes (Page 771)").
Extended Functions
3.4 Handwheel travel in JOG
3.4.1 Function
The electronic handwheels (accessories) can be used to simultaneously traverse selected
axes manually. The weighting of the handwheel graduations is dependent on the increment-
size weighting. Where coordinate offset or rotation is selected, manual travel can even be
performed in the transformed workpiece coordinate system.
Select
JOG mode must be active. The user must also set the increment INC1, INC10, etc., which
applies to handwheel travel. As with incremental travel, the required machine function must
be set at the PLC interface accordingly.
Traversing
When the electronic handwheel is turned, the associated axis is traversed either in the
positive or negative direction depending on the direction of rotation.
Note
If the axis is already being moved using the traversing keys, the handwheel cannot be used.
Traversing distance
The traversing distance produced by rotating the handwheel is dependent on the following
factors:
Number of handwheel pulses received at the interface
Active increment (machine function INC1, INC10, INC100, ... INCvar)
Pulse evaluation of the handwheel:
MD11320 $MN_HANDWH_IMP_PER_LATCH (handwheel pulses per detent position)
See Section "Parameter assignment (Page 161)".
Distance of an increment:
MD31090 $MA_JOG_INCR_WEIGHT (evaluation of an increment for INC/handwheel)
See Section "Parameter assignment (Page 161)".
Handwheel connection
Up to six handwheels can be connected simultaneously. This means that up to six axes can
be traversed by handwheel simultaneously.
Extended Functions
Representation of the handwheel number in the NC/PLC interface signals

Depending on the parameter assignment of MD11324, the representation of the handwheel
number in the NC/PLC interface signals is bit-coded (three handwheels can be represented)
or binary-coded (six handwheels can be represented).
See "Parameter assignment (Page 161)".
Handwheel assignment
It can be set as to which axis is moved by turning the handwheel:
via the PLC user interface or
via the user interface (HMI).
The assignment is linked to the NC/PLC interface through the PLC user program. In this
way, several axes can be assigned to one handwheel simultaneously.
Setting via the PLC user interface

The assignment is made using one of the following interface signals:
Machine axes:
DB31, ... DBX4.0-2 (activate handwheel <n> (1, 2, 3))
Geometry axes:
DB21, ... DBX12.0-2 (geometry axis 1: Activate handwheel <n>)
DB21, DBX16.0-2 (geometry axis 2: Activate handwheel <n>)
Orientation axes:
DB21, DBX320.0-2 (orientation axis 1: Activate handwheel <n>)
Setting via the user interface (HMI).

Pressing the "Handwheel" softkey in the JOG-mode basic menu displays the "Handwheel"
window. Here, every handwheel can be assigned an axis and the handwheel can be enabled
or disabled.
Note
The handwheel assignment is not possible via the user interface (HMI) for more than three
connected handwheels and a binary-coded representation of the handwheel number in the
NC/PLC interface signals.
Extended Functions
Handwheel selection by HMI

A separate user interface is provided between the HMI and PLC to allow activation of the
handwheel from the user interface. This interface supplied by the basic PLC program for
handwheels 1, 2 and 3 contains the following information:
Assigned to the handwheel:
Axis number (if during the handwheel selection a machine axis was selected):
DB10 DBX100.0-4 (axis number for handwheel 1)
Channel number (if during the handwheel selection a geometry axis was selected):
DB10 DBX97.0-3 (channel number for handwheel 1)
Additional information on the machine or geometry axis:
DB10 DBX100.7 (handwheel 1: Machine axis)
The information that the handwheel is enabled or disabled:
DB10 DBX100.6 (handwheel 1 selected)
For the specified axis, the basic PLC program sets the associated interface signal either to
"0" (disable) or to "1" (enable):
Machine axes:
DB31, ... DBX4.0-2 (activate handwheel <n>)
Geometry axes:
DB21, ... DBX12.0-2 (geometry axis 1: Activate handwheel <n>)
Note
Orientation axes can only be activated via the associated PLC user interface signals:
Extended Functions
Travel request
The following NC/PLC interface signal informs the PLC that an axis wants to travel or is
travelling:
Machine axes:
DB31, ... DBX64.4 (minus travel request) or
DB31, ... DBX64.5 (plus travel request)
Geometry axis 1:
DB21, DBX40.4 (geometry axis 1: Minus travel request) or
DB21, DBX40.5 (geometry axis 1: Plus travel request)
Geometry axis 2:
Geometry axis 3:
Orientation axis 1:
DB21, DBX332.4 (orientation axis 1: Minus travel request) or
DB21, DBX332.5 (orientation axis 1: Plus travel request)
Orientation axis 2:
Orientation axis 3:
Note
A travel request is the sum of all sub-movements, i.e. the component from couplings and
offset values is also taken into account.
For the method of operation of the "Travel request" function, see Section "Travel request
(Page 166)".
Extended Functions
Travel command
Depending on the setting in machine data MD11324
$MN_HANDWH_VDI_REPRESENTATION (see Section "Parameter assignment
(Page 161)"), the following interface signal is output to the PC already when a travel request
is present or not until the axis moves:
Machine axes:
DB31, ... DBX64.6 (minus travel command) or
DB31, ... DBX64.7 (plus travel command)
Geometry axis 1:
DB21, DBX40.6 (geometry axis 1: Minus travel command) or
DB21, DBX40.7 (geometry axis 1: Plus travel command)
Geometry axis 2:
Geometry axis 3:
Orientation axis 1:
DB21, DBX332.6 (orientation axis 1: Minus travel command) or
DB21, DBX332.7 (orientation axis 1: Plus travel command)
Orientation axis 2:
Orientation axis 3:
Invert handwheel direction of rotation

The handwheel direction of rotation can be inverted, if the direction of movement of the
handwheel does not match the expected direction of motion of the axis. The adaptation can
be especially necessary, if a handwheel (HT2, HT8) can be assigned to various axes.
Extended Functions
In addition to configuring the particular MD, handwheel direction of rotation inversion can be
activated by setting the IS "Invert the handwheel direction of rotation" belonging to the
particular axis:
Machine axes:
DB31, ... DBX7.0 (invert handwheel direction of rotation)
Geometry axes:
DB21, ... DBX15.0 (geometry axis 1: Invert handwheel direction of rotation)
Orientation axes:
DB21, DBX323.0 (orientation axis 1: Invert handwheel direction of rotation)
Contour handwheel:
DB21, ... DBX31.5 (invert contour handwheel direction of rotation)
Note
The inversion signal should be set in the PLC user program at the same time as the
handwheel selection (IS "Activate handwheel").
The acknowledgement that the handwheel direction of rotation has been inverted by the NC
is realized for each axis using the IS "Handwheel direction of rotation inversion active":
Machine axes:
DB31, ... DBX67.0 (handwheel direction of rotation inversion active)
Geometry axes:
DB21, ... DBX43.0 (geometry axis 1: Handwheel direction of rotation inversion active)
Orientation axes:
DB21, ... DBX335.0 (orientation axis 1: Handwheel direction of rotation inversion
active)
active)
active)
Contour handwheel:
DB21, ... DBX39.5 (contour handwheel direction of rotation inversion active)
Extended Functions
Note
It is only permissible to change the inversion signal at standstill. If the change is made while
motion setpoints are being output by the interpolator, then the signal change is rejected and
an alarm is output; further, motion is stopped taking into account the actual acceleration
value.
Abort/interruption of the traversing motion

The following NC/PLC interface signals abort the traversing motion. The setpoint/actual-
value difference is deleted.
NC/PLC interface signal Scope Effect

DB21, ... DBX7.7 (NC reset) Geometry axis / machine axis Abort
DB21, ... DBX12.0-2 (geometry axis 1: Activate Geometry axis 10 Abort
handwheel <n>)
DB21, DBX16.0-2 (geometry axis 2: Activate
handwheel <n>)
DB21, DBX20.0-2 (geometry axis 3: Activate
handwheel <n>)
DB21, ... DBX6.2 (delete distance-to-go) Geometry axis / machine axis 01 Abort
DB31, ... DBX2.2 (delete distance-to-go / spindle reset) Geometry axis / machine axis 01 Abort
DB31, ... DBX4.2 (activate handwheel <n>) Machine axis 10 Abort
DB31, ... DBX1.3 (axis/spindle disable) Geometry axis / machine axis 01 Abort
DB31, ... DBX1.5 (position measuring system 1) Geometry axis / machine axis 01 Abort
DB31, ... DBX1.6 (position measuring system 2) Geometry axis / machine axis 01 Abort
The effect of the handwheel travel (abort or interruption of the traversing motion) can be set
for other NC/PLC interface signals (stop signals) (see Section "Parameter assignment
(Page 161)").
NC STOP only interrupts the traversing movement. Any setpoint/actual-value difference is
retained. The distance-to-go is then traversed using NC START.
Limitations
The limitations are also active when traversing with the handwheel.
For further information, see Section "Monitoring functions (Page 213)".
Extended Functions
3.4.2 Parameter assignment
Distance or velocity specification

Either the distance or the velocity can be entered via the handwheel:
Distance specification (default setting)
The distance specified by the handwheel is traversed and No pulses are lost.
Limiting the velocity to the maximum permissible value causes the axes to overtravel.
Velocity specification
The handwheel only defines the traverse velocity. As soon as the handwheel stops, the
axes stop too. Motion is braked immediately if no pulses are supplied from the handwheel
in one IPO cycle, thus preventing overtravel by the axes. The handwheel pulses do not
supply a path default.
The input mode is set with machine data:
MD11346 $MN_HANDWH_TRUE_DISTANCE (handwheel distance or velocity specification)
Pulse evaluation of the handwheel

The number of pulses that are to be generated per handwheel detent position must be
specified for each handwheel:
MD11320 $MN_HANDWH_IMP_PER_LATCH [<n>] (handwheel pulses per detent position)
Note
Input of a negative value results in a reversal of the handwheel direction of rotation.
Increment size
The number of increments to be traversed by the axis per handwheel pulse is determined by
the selected increment size.
In addition to five fixed increment sizes (default setting: INC1, INC10, INC100, INC1000 and
INC10000), a variable increment size (INCvar) that can be set via the setting data is also
available.
Fixed increments
The parameter assignment of the fixed increment sizes is performed via NC-specific
machine data:
MD11330 $MN_JOG_INCR_SIZE_TAB[1 ... 5] = <number of increments 1 ... 5>
Extended Functions
Variable increment
The parameter assignment of the variable increment size is performed via NC-specific
setting data:
SD41010 $SN_JOG_VAR_INCR_SIZE = <number of increments>
Distance evaluation of one increment

The distance evaluation of one increment for fixed and variable increment sizes is performed
via the axis-specific machine data:
MD31090 $MA_JOG_INCR_WEIGHT = <distance>
Note
Input of a negative value results in a reversal of the handwheel direction of rotation.
Limitation of the increment size

The machine operator can limit the size of the selected increment:
For machine axes, using the axis-specific machine data:
MD32080 $MA_HANDWH_MAX_INCR_SIZE (limiting the selected increment)
For geometry axes, using the channel-specific machine data:
MD20620 $MC_HANDWH_GEOAX_MAX_INCR_SIZE (limitation of handwheel increment
for geometry axes)
For orientation axes, using the channel-specific machine data:
MD20621 $MC_HANDWH_ORIAX_MAX_INCR_SIZE (limitation of handwheel increment
for orientation axes)
Representation of the handwheel number in the NC/PLC interface signals

The representation of the handwheel number in the NC/PLC interface signals is defined
using machine data:
MD11324 $MN_HANDWH_VDI_REPRESENTATION
Value Meaning
0 Bit-coded representation (basic setting)
Three handwheels can be represented.
1 Binary-coded representation
Six handwheels can be represented.
Extended Functions
Output of the NC/PLC interface signals "Plus travel command" / "Minus travel command"
The output behavior of the NC/PLC interface signals "Plus travel command" / "Minus travel
command" is specified with the machine data:
MD17900 $MN_VDI_FUNCTION_MASK
Value Meaning
0 The NC/PLC interface signals "Plus travel command" / "Minus travel command" are already
output when a travel request is active (default setting).
1 The NC/PLC interface signals "Plus travel command" / "Minus travel command" are only
output when the axis actually moves (i.e. if setpoints are output at the servo).
Velocity
In handwheel travel the following axis velocities, effective during JOG mode, are used:
SD41110 $SN_JOG_SET_VELO (axis velocity for JOG)
SD41130 $SN_JOG_ROT_AX_SET_VELO (axis velocity for rotary axes for JOG mode)
MD32020 $MA_JOG_VELO (conventional axis velocity)
Because of the limited feedrate, the axis is not able to follow the handwheel rotation
synchronously, especially in the case of a large pulse weighting, and therefore overtravels.
Acceleration
As for manual travel (see "General characteristics when traversing in the JOG mode
(Page 144) ").
Movement in the opposite direction

The behavior at a reversal of the traversing direction (by turning the handwheel in the
opposite direction) can be set in the machine data:
MD11310 $MN_HANDWH_REVERSE (threshold for direction change handwheel)
Value Meaning
=0 If the handwheel is moved in the opposite direction, the resulting distance is computed and
the calculated end point is approached as fast as possible.
If this end point is located before the point where the moving axis can decelerate in the
current direction of travel, the unit is decelerated and the end point is approached by moving
in the opposite direction. If this is not the case, the newly calculated end point is approached
immediately.
>0 If the handwheel is moved in the opposite direction by at least the number of pulses
indicated in the machine data, the axis is decelerated as fast as possible and all pulses
received until the end of the interpolation are ignored.
This means that another movement takes place only after the axis reaches standstill
(setpoint side).
Extended Functions
Behavior at software limit switches, working-area limitation

When axes are traversed in JOG mode, they can traverse only up to the first active limitation
before the corresponding alarm is output.
Depending on the setting in the machine data:
MD11310 $MN_HANDWH_REVERSE (threshold for direction change, handwheel)
the behavior is then as follows (as long as the axis has still not arrived at the end point from
the setpoint side):
The distance resulting from the handwheel pulses forms a fictitious end point which is
used for subsequent calculations.
If this fictitious end point is, for example, 10 mm behind the limit, these 10 mm must be
traversed in the opposite direction before the axis traverses again. If a movement in the
opposite direction is to be performed immediately after a limitation is reached, the
fictitious distance-to-go can be deleted via delete distance-to-go or deselection of the
handwheel assignment.
All handwheel pulses leading to an end point behind the limitation are ignored. Any
movement of the handwheel in the opposite direction leads to an immediate movement in
the opposite direction, i.e. away from the limit.
Feedrate behavior
In JOG mode, the feedrate behavior of the axis/spindle also depends on the setting data:
SD41100 $SN_JOG_REV_IS_ACTIVE (JOG: Revolutional/linear feedrate)
SD41100 $SN_JOG_REV_IS_ACTIVE
Active An axis/spindle is always traversed with revolutional feedrate
MD32050 $MA_JOG_REV_VELO (revolutional feedrate for JOG)
or
MD32040 $MA_JOG_REV_VELO_RAPID
(revolutional feedrate for JOG with rapid traverse override)
depending on the master spindle.
Not active The behavior of the axis/spindle depends on the setting data:
SD43300 $SA_ASSIGN_FEED_PER_REV_SOURCE
(revolutional feedrate for positioning axes/spindles)
The behavior of a geometry axis on which a frame with rotation acts,
depends on the channel-specific setting data:
SD42600 $SC_JOG_FEED_PER_REV_SOURCE
(control of the revolutional feedrate in JOG)
Effect of the NC/PLC interface stop signals

The effect of the NC/PLC interface stop signals on the handwheel travel (abort or interruption
of the traversing motion) can be set via the machine data:
MD20624 $MC_HANDWH_CHAN_STOP_COND (definition of the handwheel travel
behavior, channel-specific)
MD32084 $MA_HANDWH_STOP_COND (handwheel travel behavior)
Extended Functions
NC/PLC interface signal Scope MD20624 $MC_HANDWH_CHAN_STOP_COND

Bit == 0 Bit == 1
DB11 DBX0.5 (mode group Geometry axis / machine Interruption until NC start Abort
stop) axis
DB11 DBX0.6 (mode group Geometry axis / machine Interruption until NC start Abort
stop, axes plus spindle) axis
DB21, ... DBX7.3 (NC Stop) Geometry axis / machine Interruption until NC start Abort
axis
DB21, ... DBX7.4 (NC stop, Geometry axis / machine Interruption until NC start Abort
axes plus spindle) axis
DB21, ... DBX6.0 (feedrate Geometry axis / machine Interruption Abort
disable) axis
DB21, ... DBB4 (feedrate Geometry axes Override == 0: Interruption if Override == 0: Abort if rapid
override) rapid traverse override is not traverse override is not
DB31, ... DBX4.5 (rapid active active
traverse override)
DB21, ... DBB5 (rapid Geometry axes Rapid traverse override == 0: Rapid traverse override == 0:
traverse override) Interruption if rapid traverse Abort if rapid traverse
DB31, ... DBX4.5 (rapid override is active override is active
traverse override)
DB21, ... DBX12/16/20.3 Geometry axis Interruption Abort
(geometry axis 1/2/3:
Feedrate stop)
NC/PLC interface signal Scope MD32084 $MC_HANDWH_CHAN_STOP_COND

Bit == 0 Bit == 1
DB31, ... DBB0 (axial Machine axis, not spindle Override == 0: Interruption Override == 0: Abort
feedrate override)
DB31, ... DBB19 (spindle Spindle Override == 0: Interruption Override == 0: Abort
override)
DB31, ... DBX4.3 (feedrate Geometry axis / machine Interruption Abort
stop / spindle stop) axis
DB31, ... DBX2.3 (clamping Geometry axis / machine No effect Abort
in progress) axis
DB31, ... DBX2.1 (control Geometry axis / machine Interruption Abort
system enable) axis
DB31, ... DBX21.7 (pulse Geometry axis / machine Interruption Abort
enable) axis
Note
Removal of the "Controller enable" and "Pulse enable" during traversing results in a rapid
stop of the axis and a reset alarm.
Extended Functions
Interruption of a traversing motion

When a stop command is issued, the distance-to-go is saved and the handwheel pulses are
collected. When the stop condition no longer applies, the resulting distance is traversed.
Abort of a traversing motion

When a stop command is issued, the distance-to-go is deleted and the handwheel pulses
are ignored (i.e. not collected) until the stop condition no longer applies.
3.4.3 Travel request

The following examples are intended to illustrate the method of operation of the "Travel
request" NC/PLC interface signal.
Example 1: Handwheel travel with distance specification, stop condition is not an abort criterion
If a stop condition that is present is not an abort criterion (see
MD32084 $MA_HANDWH_STOP_COND or
MD20624 $MC_HANDWH_CHAN_STOP_COND) during handwheel travel with distance
specification (MD11346 $MN_HANDWH_TRUE_DISTANCE == 1 or == 3), then the output of
the NC/PLC interface signals "Travel request" and "Travel command" corresponds to the
behavior in the two figures below.
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Handwheel travel with distance specification, stop condition is not an abort criterion
MD17900 $MN_VDI_FUNCTION_MASK bit 0 = 0
Extended Functions

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Handwheel travel with distance specification, stop condition is not an abort criterion
MD17900 $MN_VDI_FUNCTION_MASK bit 0 = 1
Example 2: Handwheel travel, stop condition is an abort criterion

If a stop condition is selected as an abort criterion via machine data
MD32084 $MA_HANDWH_STOP_COND or
MD20624 $MC_HANDWH_CHAN_STOP_COND during handwheel travel, no travel
command is output, but the corresponding travel request is output.
When the stop condition is removed, the corresponding "Travel request" NC/PLC interface
signal is reset, as an abort is present. The stop condition is no longer active, but the axis
cannot be traversed as the stop condition has caused an abort.
In addition, either the distance specification (MD11346 $MN_HANDWH_TRUE_DISTANCE
== 1 or == 3) is active or the handwheel is moved continuously, i.e. it provides pulses.
Extended Functions
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Handwheel travel, stop condition is an abort criterion
If a stop condition is activated during the handwheel travel, the motion is aborted and the
"Travel request" and "Travel command" NC/PLC interface signals are reset.
Example 3: Handwheel travel with velocity specification, stop condition is an abort criterion
If the handwheel is no longer moved for velocity specification
(MD11346 $MN_HANDWH_TRUE_DISTANCE == 0 or == 2), the "Travel request" NC/PLC
interface signal is reset.
The "Travel request" PLC signal is also reset when the handwheel is deselected.

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Handwheel travel with velocity specification, stop condition is an abort criterion
Extended Functions
Supplementary conditions
NC stop
With NC stop present, no travel command and, therefore, no travel request is output. There
is an exception with DRF travel: If DRF travel is permitted in the NC stop state via machine
data MD20624 $MC_HANDWH_CHAN_STOP_COND (bit 13 == 1), the behavior
corresponds to that of handwheel travel.
3.4.4 Double use of the handwheel
Alarm 14320
The double use of a handwheel for DRF and velocity or distance overlay, including contour
handwheel, is suppressed and is displayed using the self-clearing alarm 14320 (Handwheel
%1 used twice (%2) in channel %3 axis %4), if, different influences can act on an axis as a
result of the handwheel.
This means that an overlaid movement can only be executed when no DRF offset (triggered
by the same handwheel) is active for the axes in the basic coordinate system that are
involved in the movement, i.e., the DRF movement must have been terminated.
If an overlaid movement has been started, no DRF offset can be started for any of the axes
involved that are supplied by the same handwheel. Such a DRF movement is only possible
when the movement with overlay has reached its end point or has been aborted by delete
distance-to-go or RESET.
If the handwheel override and DRF offset are to be active simultaneously, this is possible
with activation of two separate handwheels.
Example: Path override

Assumption:
Channel 1 and geometry axis X correspond to machine axis 3 and geometry axis Y
corresponds to machine axis 5 and handwheel 2 is selected for the first geometry axis.
If block X10 Y10 FD=0 is processed in the main run, neither machine axis 3 nor machine
axis 5 can be traversed with DRF via handwheel 2. If handwheel 2 is assigned to machine
axis 3 while the channel-specific DRF signal is active, then alarm 14320 (Handwheel 2 used
twice (8) in channel 1 axis X) is signaled.
If machine axis 3 or machine axis 5 is traversed with DRF using the 2nd handwheel, then
motion X10 Y10 FD=0 cannot be executed and alarm 14320 (handwheel 2 used twice (3) in
channel 1 axis X) or alarm 14320 (handwheel 2 used twice (3) in channel 1 axis Y) is
signaled.
Extended Functions
3.5 Handwheel override in automatic mode
Example: Velocity override of positioning axis

Assumption:
Channel 1: Channel axis A corresponds to machine axis 4 and handwheel 1 is assigned to
this axis.
If block POS[A]=100 FDA[A]=0 is processed in the main run, machine axis 4 cannot be
traversed with DRF. This means that if the channel-specific DRF signal is active, alarm
14320 (Handwheel 1 used twice (6) in channel 1 axis A) is signaled.
If machine axis 4 is traversed with DRF, then no POS[A]=100 FDA[A]=0 movement can be
executed while a DRF movement is being performed. Alarm 14320 (Handwheel 1 used twice
(1) in channel 1 axis A) is signaled.
Example: Distance overlay PLC axis (840D sl)

Assumption:
Channel 1: Handwheel 2 is assigned to machine axis 4.
If an axis movement with path override of the 4th machine axis triggered by FC18 is
processed in the main run, machine axis 4 cannot be traversed with DRF. This means that if
the channel-specific DRF signal is active, alarm 14320 (Handwheel 2 used twice (9) in
channel 1 axis A) is signaled.
If machine axis 4 is traversed with DRF, then no axis movement with path override triggered
by FC18 can be executed while a DRF movement is being performed. Alarm 14320
(Handwheel 2 used twice (4) in channel 1 axis A) is signaled.
Function
With this function it is possible to traverse axes or to change their velocities directly with the
handwheel in automatic mode (Automatic, MDA).
The handwheel override is activated in the NC part program using the NC language
elements FD (for path axes) and FDA (for positioning axes) and is non-modal.
With positioning axes, it is possible to activate the handwheel override modally using
traverse command POSA. When the programmed target position is reached, the handwheel
override becomes inactive again.
Additional axes can be traversed simultaneously or using interpolation in the same NC block.
The concurrent-positioning-axes function can also be activated by the PLC user program.
Extended Functions
Distinction
Depending on the programmed feedrate, a distinction is made between the following for
handwheel override:
Path definition
Axis feedrate = 0 (FDA = 0)
Velocity override
Axis feedrate > 0 (FD or FDA > 0)
The table below shows which axis types can be influenced by the "handwheel override in
automatic mode" function.
Axes that can be influenced by the "handwheel override in automatic mode" function
Axis type Velocity override Path definition
Positioning axis FDA[AXi] > 0 ; FDA[AXi] = 0
acts axially
Concurrent Parameter "Handwheel override active" = 1 and Parameter "Handwheel
positioning axis axis feedrate > 0 from FC18 override active" = 1 and axis
feedrate = 0 from FC18
Path axis FD > 0 ; Not possible
acts on path velocity
Path definition
With axis feedrate = 0 (e.g. FDA[AXi] = 0), the traversing movement of the positioning axis
towards the programmed target position is controlled entirely by the user rotating the
assigned handwheel.
The direction in which the handwheel is turned determines the traversing direction of the
axis. The programmed target position cannot be exceeded during handwheel override. The
axis can also be moved toward the programmed target position from the opposite direction,
whereby the movement is only restricted by the axial position limitations.
A block change occurs when:
The axis has reached the programmed target position
or
The distance-to-go is deleted by axial interface signal
DB31, ... DBX2.2 (delete distance-to-go).
From this moment on, the path default is deactivated and any further handwheel pulses have
no effect.
After this, incrementally programmed positions refer to the point of interruption and not to the
last programmed position.
Extended Functions
Velocity override
With regard to the velocity override, a distinction is made between axis feedrate and path
feedrate.
Axis-velocity override (FDA[AXi] > 0):
The positioning axis is moved to the target position at the programmed axial feedrate.
Using the assigned handwheel, it is possible to increase the axis velocity or to reduce it to
a minimum of zero depending on the direction of rotation. The resulting axis feedrate is
limited by the maximum velocity. However, the axis cannot be traversed in the opposite
direction to that programmed.
The block change is performed as soon as the axis reaches the programmed target
position. This causes the velocity override to be deactivated automatically and any further
handwheel pulses have no effect.
Similarly, this also applies to concurrent positioning axes, where the target position and
the velocity are defined by the PLC.
Path-velocity override (FD > 0):
The path axes programmed in the NC block traverse to the target position at the
programmed feedrate. If the velocity override is active, the programmed path velocity is
overridden by the velocity generated with the handwheel of the 1st geometry axis. The
block change is performed as soon as the programmed target position is reached.
The path velocity is increased or reduced to a minimum of zero depending on the
direction of rotation of the handwheel. However, it is not possible to reverse the direction
of movement with handwheel override.
Application example
The "Handwheel override in automatic mode" function is frequently used on grinding
machines. For example, the user can position the reciprocating grinding wheel on the
workpiece using the handwheel (path default). After scratching, the traversing movement is
terminated and the block change is initiated (by activating DB31, ... DBX2.2 (delete distance-
to-go)).
Preconditions
In order to activate "Handwheel override in automatic mode", the following requirements
must have been met:
A handwheel must be assigned to the axis in question.
Pulse weighting exists for the assigned handwheel.
Extended Functions
Handwheel assignment
The assignment of the connected handwheels to the axes is analogous to the "Handwheel
travel in JOG (Page 154)" via the user interface or via the PLC user interface with one of the
following interface signals:
Machine axes:
DB31, ... DBX4.0-2 (activate handwheel (1, 2, 3))
Geometry axes:
DB21, ... DBX12.0-2 (geometry axis 1: Activate handwheel (1, 2, 3))
DB21, DBX16.0-2 (geometry axis 2: Activate handwheel (1, 2, 3))
DB21, DBX20.0-2 (geometry axis 3: Activate handwheel (1, 2, 3))
If handwheel override is programmed for an axis to which no handwheel is assigned, a
distinction is made between the following cases:
For velocity override:
The axes traverse at the programmed velocity.
A self-acknowledging alarm is output (without response).
For path definition:
No traversing movement is performed because the velocity is zero.
A self-acknowledging alarm is output (without response).
Note
When the velocity override is applied to path axes, only the handwheel of the 1st
geometry axis acts on the path velocity.
Handwheel weighting
The traverse path of the axis that is generated by rotating the handwheel by one detent
position is dependent on several factors (see Section "Handwheel travel in JOG
(Page 154)"):
Selected increment size:
MD11330 $MN_JOG_INCR_SIZE_TAB[5] (increment size for INC/handwheel)
or
SD41010 $SN_JOG_VAR_INCR_SIZE (size of the variable increment for JOG)
Weighting of an increment:
MD31090 $MA_JOG_INCR_WEIGHT
Number of handwheel pulses per detent position:
MD11320 $MN_HANDWH_IMP_PER_LATCH
For example, the axis traverses by 0.001 mm per handwheel detent position if machine
function INC1 and the default setting of the above machine data are selected.
In the case of velocity override, the velocity results from the traverse path covered using the
handwheel within a certain period of time.
Extended Functions
Example
Assumptions:
The operator turns the handwheel with 100 pulses/second.
The selected machine function is INC100.
The default setting is made for the above machine data for handwheel weighting.
Handwheel traverse path per second: 10 mm

Velocity override: 0.6 m/min
PLC interface signals

As soon as the handwheel override takes effect, the following interface signals to the PLC
are set to signal 1:
For positioning axes / concurrent positioning axes / command axes / reciprocating axes:
DB31, ... DBX62.1 (handwheel override active)
For path axes:
For the path input, depending on the traversing direction, the appropriate interface signals
are output to the PLC:
Machine axes:
DB31, ... DBX64.6/7 (traversing command minus/plus)
Geometry axes:
DB21, DBX40.6/7 (geometry axis 1: traversing command minus/plus)
Limitations
The axial limitations (software limit switch, hardware limit switch, working-area limitation) are
effective in conjunction with handwheel override. With path default, the axis can be traversed
with the handwheel in the programmed traversing direction only as far as the programmed
target position.
The resulting velocity is limited by the axial machine data:
MD32000 $MA_MAX_AX_VELO(maximum axis velocity)
Extended Functions
NC Stop/override = 0
If the feedrate override is set to 0% or an NC Stop is initiated while the handwheel override is
active, the following applies:
For path definition:
The handwheel pulses arriving in the meantime are summated and stored. If NC Start or
the feedrate override > 0%, the saved handwheel pulses become effective (i.e. are
traversed).
However, if the handwheel is first deactivated [via IS DB21, ... DBX12/16/20.0-2
(geometry axes 1/2/3: Activate handwheel (1, 2, 3))] then the stored handwheel pulses
are deleted.
For velocity specification:
The handwheel pulses arriving in the meantime are not summated and are not active.
3.5.2 Programming and activating handwheel override
General information
When the handwheel override is programmed with NC language elements FD (for path axes)
and FDA (for positioning axes), the following points must be observed:
FDA and FD function non-modally.
Exception for positioning axes: If traverse instruction POSA is programmed, the handwheel
override can also act modally because this positioning axis does not affect the block
transition.
When the handwheel override is activated with FDA or FD, a target position must be
programmed in the NC block for the positioning axis or for a path axis. When the
programmed target position is reached, the handwheel override becomes inactive again.
It is not possible to program FDA and FD or FA and F in the same NC block.
The positioning axis must not be an indexing axis.
Positioning axis
Syntax for handwheel override: FDA[AXi] = [feedrate value]
Example 1:
Activate velocity override
N10 POS[U]=10 FDA[U]=100 POSA[V]=20 FDA[V]=150 . . .
POS[U]=10
Target position of positioning axis U
FDA[U]=100
Activate velocity override for positioning axis U; axis velocity of U =
100 mm/min
POSA[V]=20
Target position of positioning axis V (modally)
FDA[V]=150
Activate velocity override for positioning axis V; axis velocity of V =
150 mm/min
Extended Functions
Example 2:
Activate path default and velocity override in the same NC block
N20 POS[U]=100 FDA[U]= 0 POS[V]=200 FDA[V]=150 . . .
POS[U]=100
Target position of positioning axis U
FDA[U]= 0
Activate path default for positioning axis U;
POS [V]=200
Target position of positioning axis V
FDA[V]=150
Activate velocity override for positioning axis V; axis velocity of V =
150 mm/min
Path axis
Syntax for handwheel override: FD = [feedrate value]
In order to activate "Handwheel override in automatic mode", the following requirements

must have been met:
Active movement commands from group 1: G01, G02, G03, CIP
Exact stop active (G60)
Linear feedrate in mm/min or inch/min active (G94)
These requirements are checked by the control and an alarm is output if any of them is not
met.
Example 3:
Activate velocity override
N10 G01 X10 Y100 Z200 FD=1500 . . .
X10 Y100 Z200

Target position of path axes X, Y and Z
FD=1500
Activate velocity override for path axes; path velocity = 1500
mm/min
Concurrent positioning axis

The handwheel override for concurrent positioning axes is activated from the PLC via FC18
by setting the appropriate interface signal:
If the velocity parameter (F_Wert) is transferred with the value 0, then the activated
handwheel override acts as distance input, i.e. in this case, the feed is not derived from the
axial machine data (see also Section "P2: Positioning axes (Page 599)"):
MD32060 $MA_POS_AX_VELO (initial setting for positioning axis velocity)
References:
Function Manual, Basic Functions, Basic PLC Program (P3)
Extended Functions
3.5.3 Special features of handwheel override in automatic mode
Velocity display
The velocity display for handwheel override shows the following values:
Set velocity
= programmed velocity
Actual velocity
= resultant velocity including handwheel override
Effect on transverse axes

If the axis is defined as a transverse axis and DIAMON is active, the handwheel pulses are
interpreted and traversed as diameter values while handwheel override is active.
Dry-run feedrate
With active dry run
DB21, ... DBX0.6 (activate dry-run feedrate) = 1,
the dry-run feedrate is always effective
SD42100 $SC_DRY_RUN_FEED.
In this way, the axis is traversed to the programmed target position at dry-run feedrate
without any influence from the handwheel despite the active handwheel override with path
default (FDA[AXi] = 0), i.e., the path default is ineffective.
DRF active
When "Handwheel override in automatic mode" is activated, it is important to check whether
the "DRF" function is active (DB21, ... DBX0.3 = 1).
If this were the case, the handwheel pulses would also cause a DRF offset of the axis. The
user must, therefore, first deactivate DRF.
Feedrate override
The feedrate override does not affect the velocity of the movements produced by the
handwheel (exception: 0%). It only affects the programmed feedrate.
With path default and fast handwheel movements, the axis may not be able to follow the
handwheel rotation synchronously (especially in the case of a large handwheel-pulse
weighting), causing the axis to overtravel.
Extended Functions
3.6 Contour handwheel/path input using handwheel (option)
Function
When the function is activated, the feedrate of path and synchronized axes can be controlled
via a handwheel in AUTOMATIC and MDI modes.
Availability
For the SINUMERIK 840D sl and SINUMERIK 828D systems, the "contour handwheel"
function is available as an option that is under license.
Input mode (path or velocity input)

Either the distance or the velocity can be entered via the handwheel:
Path definition
Limiting the velocity to the maximum permissible value causes the axes to overtravel. The
path defined by the handwheel is traversed and no pulses are lost.
Velocity specification
The handwheel only defines the traverse velocity. As soon as the handwheel stops, the
axes stop too. Motion is braked immediately if no pulses are supplied from the handwheel
in one IPO cycle, thus preventing overtravel by the axes. The handwheel pulses do not
supply a path default.
The input mode is set with machine data:
MD11346 $MN_HANDWH_TRUE_DISTANCE (handwheel distance or velocity input)
Feedrate
The feedrate in mm/min is dependent on:
The number of pulses supplied by the selected handwheel within one period
Pulse evaluation of the handwheel via the machine data:
MD11322 $MN_CONTOURHANDWH_IMP_PER_LATCH (contour handwheel pulses per
detent position)
The activated increment (INC1, 10, 100, etc.)
The distance weighting of an increment of the first available geometry axis:
MD31090 $MA_JOG_INCR_WEIGHT (evaluation of an increment for INC/handwheel)
The feedrate is not dependent on:
The programmed feedrate mode (mm/min, mm/rev.)
The programmed feedrate (resultant velocity can be higher)
The rapid traverse velocity for G0 blocks
The override (position 0% is effective, i.e. zero speed)
Extended Functions
Traversing direction
The traversing direction depends on the direction of rotation:
Clockwise
Results in travel in the programmed direction
If the block-change criterion (IPO end) is reached, the program advances to the next
block (response identical to G60).
Counterclockwise
Results in travel in the programmed direction
Here, the axes can only traverse to the appropriate block start. Pulses are not collected if
the handwheel continues to rotate.
Activation of the function

The function can be activated via interface signals or via the NC program:
Activation via interface signal
Switching-in/switching-out is realized via the interface signal:
DB21, ... DBX30.0-2 (activate contour handwheel (1, 2, 3))
Activation via the NC program
The contour handwheel can be activated in the NC program non-modally using FD=0, that
is, velocity F... from the block before the contour handwheel applies in the following
block without the need for additional programming.
Note
If no feedrate was programmed in the previous blocks, a corresponding alarm is output.
FD and F cannot appear in the same NC block (triggers an alarm).
Contour-handwheel simulation
When the contour handwheel is activated, it can also be simulated.
After activation via interface signal
DB21, ... DBX30.3 (contour-handwheel simulation),
the feedrate is no longer defined by the contour handwheel; the programmed feedrate is
used instead.
The direction is also defined via an interface signal:
DB21, ... DBX30.4 (negative direction simulation contour handwheel)
When the simulation is deselected or the direction is changed, the current movement is
decelerated using a braking ramp.
Note
The override is effective as for NC-program execution.
Extended Functions
3.7 DRF offset
Boundary conditions
Preconditions
Fixed feedrate, dry-run feedrate, thread cutting, or tapping must not be selected.
Limit values
The acceleration and velocity of the axes are limited to the values defined in the machine
data.
Interruption of traversing movement
On NC Stop, the function remains selected but the handwheel pulses are not summated
and are ineffective.
Precondition: MD32084 $MA_HANDWH_CHAN_STOP_COND bit 2 = 1
DRF
A selected DRF function also has a path-override action.
Channel-specific deletion distance-to-go
This causes the movement triggered by the contour handwheel to be aborted; the axes
are decelerated and the program is restarted with the next NC block. The contour
handwheel then becomes effective again.
3.7 DRF offset
Function
The "DRF offset" function (differential resolver function) can be used to set an additive
incremental zero offset in respect of geometry and auxiliary axes in the basic coordinate
system in AUTOMATIC mode via an electronic handwheel.
The handwheel assignment, i.e. the assignment of the handwheel from which the increments
for the DRF offset are to be derived, to the geometry or auxiliary axes that are to be moved
by this, must be performed via the appropriate machine axes. The appropriate machine axes
are those to which the geometry or auxiliary axis is mapped.
The DRF offset is not displayed in the axis actual-value display.
Applications
The DRF offset can be used, for example, in the following application cases:
Offsetting tool wear within an NC block
Where NC blocks have very long processing times, it becomes necessary to offset tool
wear manually within the NC block (e.g. large surface-milling machines).
Highly precise offset during grinding
Simple temperature compensation
Note
The zero offset introduced via the DRF offset is always effective in all modes and after a
RESET. It can, however, be suppressed non-modally in the part program.
Extended Functions
3.7 DRF offset
Velocity reduction
The velocity generated using the handwheel for DRF can be reduced with respect to the
JOG velocity:
MD32090 $MA_HANDWH_VELO_OVERLAY_FACTOR (ratio of JOG velocity to handwheel
velocity (DRF))
DRF active
DRF must be active to allow the DRF offset to be modified by means of traversal with the
handwheel. The following requirements must be fulfilled:
AUTOMATIC mode
DB21, ... DBX0.3 (activate DRF) = 1
The DRF offset can be activated/deactivated for specific channels using the "program
control" function on the HMI user interface.
The HMI software then sets interface signal:
DB21, ... DBX24.3 (DRF selected) =1.
The PLC program (basic PLC program or user program) transfers this interface signal to
interface signal
DB21, ... DBX0.3 (activate DRF) once the corresponding logic operation has been
performed.
Control of DRF offset

The DRF offset can be modified, deleted or read:
User: Traversing with the handwheel

Part program: Reading via axis-specific system variable $AC_DRF[<axis>]
Deleting via parts-program command (DRFOF) for all axes in a
channel
Non-modal suppression via parts-program command (SUPA)
References:
Programming Manual, Fundamentals
PLC user program: Reading the DRF offset (axis-specific)
References:
Function Manual, Basic Machine; PLC Basic Program (P3)
HMI user interface: Display of the DRF offset (axis-specific)
Note
If DRF offset is deleted, the axis is not traversed!
Extended Functions
3.7 DRF offset
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Display
The axis actual-position display (ACTUAL POSITION) does not change while an axis is
being traversed with the handwheel via DRF. The current axis DRF offset can be displayed
in the DRF window.
Reference point approach

In phase 1 of the machine-axis reference point approach, the DRF offset for the
corresponding geometry or auxiliary axis is deleted.
During the machine-axis reference point approach, a DRF offset for the corresponding
geometry or auxiliary axis cannot be performed simultaneously.
Reset response
PowerOn-Reset: The DRF offset is deleted.
Extended Functions
3.8 Approaching a fixed point in JOG
3.8.1 Introduction
Function
The machine user can use the "Approaching fixed point in JOG" function to approach axis
positions defined through machine data by actuating the traverse keys of the machine
control table. The traveling axis comes to a standstill automatically on reaching the defined
fixed point.
Applications
Typical applications are, for example:
Approaching a basic position before starting an NC program.
Travel towards tool change points, loading points and pallet change points.
Requirements
The "Approaching fixed point in JOG" can be activated only in the JOG mode.
The function cannot be enabled in the JOG-REPOS and JOG-REF sub-modes and in
JOG in the AUTOMATIC mode.
The axis to be traversed must be referenced.
A kinematic transformation may not be active.
The axis to be traversed may not be a following axis of an active coupling.
Approaching a fixed point with G75

The process for approaching defined fixed points can also be activated from the part
program using the G75 command.
For more information on fixed point approach with G75 please refer to:
References:
Programming Manual, Fundamentals; Section: "Additional commands" > "Approach fixed
point (G75)".
Extended Functions
3.8.2 Functionality
Procedure
Procedure in "Approaching fixed point in JOG"
Selection of JOG mode
Enabling the "Approach fixed point in JOG" function
Traversing of the machine axis with traverse keys or handwheel
Activation
After selecting the "Approach fixed point in JOG" function, the PLC outputs the number of
the fixed point to be approached binary coded to the NC using the following bits:
DB31, ... DBX13.0-2 (JOG approach fixed point)
The NC confirms the activation with the interface signal as soon as the function is effective:
DB31, ... DBX75.0-2 (JOG approach fixed point active)
Note
Activation is not possible:
during an NCK reset
In case of impending emergency stop
During processing of an ASUP
No alarm message occurs. Delayed activation takes place after closure or after
acknowledgement of the active function.
Sequence
The actual traversing is started with the traverse keys or the handwheel in the direction of
the approaching fixed point.
The selected machine axis traverses till it comes to an automatic standstill at the fixed point.
The corresponding NC/PLC interface signal is reported on reaching the fixed point with
"Exact stop fine":
DB31, ... DBX75.3-5 (JOG approach fixed point reached)
This display signal is also signaled if the axis reaches the fixed point position in the machine
coordinates system via other methods e.g. NC program, FC18 (for 840D sl) or synchronized
action on the setpoint side and comes to a standstill on the actual value side within the
"Exact stop fine" tolerance window (MD36010 $MA_STOP_LIMIT_FINE).
Extended Functions

The response while traversing in the opposite direction, i.e.,against the direction of the
approaching fixed point depends on the setting of Bit 2 in the machine data:
MD10735 $MN_JOG_MODE_MASK (settings for the JOG mode)
Traverse in the opposite direction is possible only if the bit is set.
Traverse in the opposite direction is blocked if the bit is not set and the following channel
status message is output if an attempt is made with the traverse keys or with the handwheel
to traverse in the direction opposite the approaching fixed point:
"JOG: <Axis> direction blocked"
Approaching other fixed point

The axis motion is cancelled and the following alarm is output if a different fixed point is
selected while traversing to the fixed point:
Alarm 17812 "Channel %1 Axis %2 fixed point approach in JOG: Fixed point changed"
The message signal DB31, ... DBX75.0-2 (JOG - Approaching fixed point active) displays the
number of the newly selected fixed point. The JOG traverse must be triggered again to
continue traversing.
Note
To avoid the alarm message, the machine user should proceed as follows:
1. Cancel the current traverse movement with residual distance deletion.
2. Activate fixed point approach for another fixed point and start the operation after the axis
comes to a standstill.
Withdrawal from fixed point / deactivation

To withdraw from a fixed position, you must deactivate the "Approaching fixed point in JOG"
function. This is done by resetting the activation signal to "0".
DB31, ... DBX13.0-2 = 0
The message signals DB31, ... DBX75.0-2 (JOG - Approaching fixed point active) and
DB31, ... DBX75.3-5 (JOG - Approaching fixed point reached) are deleted on leaving the
fixed point position.
Special case: Axis is already on fixed point

The axis cannot be moved if, while starting the fixed point traverse, the axis is already at the
position of the fixed point to be approached. This is displayed through the following channel
status message:
"JOG: <Axis> position reached"
To withdraw from the fixed position, you must deactivate the "Approaching fixed point in
JOG" function.
Extended Functions
Special features of incremental travel

If, during incremental travel, the fixed point is reached before the increment is completed,
then the increment is considered to have been completed fully. This is the case even when
only whole increments are traveled.
MD11346 $MN_HANDWH_TRUE_DISTANCE = 2 or 3
Features of modulo rotary axes

Modulo rotary axes can approach the fixed point in both directions. The shortest path (DC) is
not observed during the travel.
Features of spindles
A spindle changes to the positioning mode on actuating the "Approaching fixed point in JOG"
function. The closed loop position control is active and the axis can traverse to the fixed
point.
If no zero mark is detected the alarm message in the axis operation is output:
Alarm 17810 "Channel %1 Axis %2 not referenced"
As a spindle must also be a modulo rotary axis at all times, the same conditions apply for
direction observation as for modulo rotary axes (refer to the paragraph "Features of modulo
rotary axes")
3.8.3 Parameterization

The behavior while traversing in the opposite direction - i.e. in the direction opposite to
approaching the fixed point - depends on the following setting:
MD10735 $MN_JOG_MODE_MASK, bit 2 (settings for the JOG mode)
Bit Value Meaning

2 0 Travel in the opposite direction is not possible (default setting).
1 Movement in the opposite direction is possible.
Fixed point positions

Up to four fixed point positions can be defined for an axis:
MD30600 $MA_FIX_POINT_POS[0...3] = <fixed point position 1...4>
Extended Functions
Number of valid fixed point positions

The number of fixed point positions entered in MD30600 $MA_FIX_POINT_POS that are
actually valid, can be defined using:
MD30610 $MA_NUM_FIX_POINT_POS = <number of valid fixed point positions>
Note
Exception: G75
For compatibility reasons, the following parameter assignment is also possible for G75:
MD30610 $MA_NUM_FIX_POINT_POS = 0 (no valid fixed point positions)
it is assumed that there are two valid fixed point positions in MD30600
$MA_FIX_POINT_POS[0] and [1].
Fixed point positions 1 and 2 can be activated via the NC/PLC interface, however they can
only be approached via G75.
Axis dynamics
The axial acceleration and the axial jerk for "Approaching fixed point in JOG" are determined
by the following machine data:
When traversing with traverse keys or handwheel:
MD32301 $MA_JOG_MAX_ACCEL (maximum axial acceleration for JOG movements)
MD32436 $MA_JOG_MAX_JERK (maximum axial jerk for JOG movements)
Note
MD32436 $MA_JOG_MAX_JERK is only effective when the axial jerk limitation for
single-axis movements has been enabled for the machine axes to be traversed:
MD32420 $MA_JOG_AND_POS_JERK_ENABLE [<axis>] == TRUE
During traversing via the G75 part program command:

MD32300 $MA_MAX_AX_ACCEL [0/1] (maximum axial acceleration for path motions
in the dynamic response mode DYNNORM/DYNPOS)
Note
The type of positioning axis dynamics (DYNNORM or DYNPOS) is defined by the
machine data:
MD18960 $MN_POS_DYN_MODE = <mode>
Extended Functions
MD32431 $MA_MAX_AX_JERK [0] (maximum axial jerk for path motions in the
dynamic response mode DYNNORM)
Note
MD32431 $MA_MAX_AX_JERK is only effective when the axial jerk limitation for
single-axis movements has been enabled for the machine axes to be traversed:
MD32420 $MA_JOG_AND_POS_JERK_ENABLE [<axis>] == TRUE
Reference:
3.8.4 Programming
System variables
The following system variables that can be read in the part program and in the synchronous
actions for the "Approach fixed point" function.

$AA_FIX_POINT_SELECTED [<Axis>] Number of fixed point to be approached
$AA_FIX_POINT_ACT [<Axis>] Number of the fixed point on which the axis is
currently located
3.8.5 Supplementary Conditions
Axis is indexing axis

The axis is not traversed and an alarm is output if the axis to be traversed is an indexing axis
and the fixed point position to be approached does not match an indexing position.
Frames active
All active frames are ignored. Traversing is performed in the machine coordinate system.
Extended Functions
Offset values active

Active offset values (DRF, external zero offset, synchronized action offset $AA_OFF, online
tool offset) are also traversed. The fixed point is a position in the machine coordinates
system.
An alarm is issued if an offset movement (DRF, external zero offset, synchronized action
offset $AA_OFF, online tool offset) is made during a fixed point approach in JOG. The
position of the fixed point to be approached in the machine coordinates system is not
reached; instead a position that would have been reached without active offset movement is
reached. The NC/PLC interface signal DB31, ... DBX75.3-5 corresponding to the fixed point
is not output.
Working-area limitations
Working-area limitations (in BCS and WCS) are considered and the axis motion is stopped
on reaching the limits.
3.8.6 Application example
Target
A rotary axis (machine axis 4 [AX4]) is to be moved to Fixed Point 2 (90 degrees) with the
"Approaching fixed point in JOG" function.
Parameter setting
The machine data for the "Approaching fixed point" function of machine axis 4 are
parameterized as follows:
MD30610 $MA_NUM_FIX_POINT_POS[AX4] = 4 4 fixed points are defined for machine

axis 4.
MD30600 $MA_FIX_POINT_POS[0,AX4] = 0 1st Fixed point of AX4 = 0 degree
MD30600 $MA_FIX_POINT_POS[1,AX4] = 90 2nd Fixed point of AX4 = 90 degree
MD30600 $MA_FIX_POINT_POS[2,AX4] = 180 3rd Fixed point of AX4 = 180 degree
MD30600 $MA_FIX_POINT_POS[3,AX4] = 270 4th Fixed point of AX4 = 270 degree
Initial situation
Machine axis 4 is referred and is in Position 0 degree. This corresponds to the 1st fixed
position and is output through the NC/PLC interface signal:
DB31 DBX75.0 = 1 (Bit 0-2 = 1)
Extended Functions
3.9 Retraction in the tool direction (JOG retract)
Approaching fixed point 2

The control is switched in the JOG mode.
The "Approaching fixed point" function is activated on Fixed Point 2 via the NC/PLC interface
signal:
DB31 DBX13.1 = 1 (Bit 0-2 = 2)
The actuation is confirmed via the NC/PLC interface signal:
DB31 DB75.1 = 1 (Bit 0-2 = 2)
The Plus traverse key in the machine control table is used to traverse continuously to
approach Fixed Point 2.
The machine axis 4 stops at the 90 degree position. This is reported via the NC/PLC
interface signal:
DB31 DBX75.4 = 1 (Bit 3-5 = 2)
3.9.1 Overview
Function
The function "Retraction in the tool direction in the JOG retract submode", called "JOG
retract" in the following, supports the manual tool retraction in the workpiece coordinate
system (WCS) after a program abort through a power off of the control or a channel reset in
the AUTOMATIC or MDI mode.
In particular, the specific features of the following functions are taken into account:
Tapping with compensating chuck and speed-controlled spindle with encoder (G33)
Tapping without compensating chuck and position-controlled spindle (G331, G332)
Machining with tool orientation with swivel cycle CYCLE800 or orientation transformation
Availability
The JOG retract function can be selected only when:
Tapping using G33/G331/G332
or general:
A machining with a drilling tool (tool type 200 to 299)
has been interrupted with a channel reset or power off.
Extended Functions
Data to be restored
In order to be able to execute the retraction in the tool direction after a program abort, the
following data which was active in the channel before the program abort, is restored:
Active tool offset
Active machining plane
Active tool carrier
Active transformation data block with transformation parameters
Data of the thread group with G33 or G331/G332
Positions of the axes that are involved in the transformation
If this data is completely available after a program abort, it is restored in the channel when
the JOG retract submode is selected. In this case, the workpiece coordinate system (WCS)
is aligned by the control in such a way that one of the geometry axes is in the direction of the
tool axis. The tool retraction can then be performed manually by traversing this geometry
axis.
Note
Data backup
The specified data itself is not backed up, only the references to this data. If the data is
changed prior to the selection of JOG retract, the function is performed on the basis of the
changed data.
Restrictions
Programs that can be started by interrupt signals are not executed in JOG retract.
3.9.2 Parameter assignment
Automatic selection of JOG retract after Power On

After the control has run up (Power On), the channels are in the parameterized default
mode:
MD10720 $MN_OPERATING_MODE_DEFAULT[<mode group>] = <default mode>
The following machine data can be set so that when the control has run up, JOG mode is
selected irrespective of the parameterized default mode. However, the selection is only
performed when the mode group retraction data is available in a channel.
Extended Functions
MD10721 $MN_OPERATING_MODE_EXTENDED[<mode group>] = <value>

Value Meaning
0 Selection of the operating mode corresponding to MD10720
$MN_OPERATING_MODE_DEFAULT
1 Selection of JOG mode, if: DB21, ... DBX377.5 == 1 ("retraction data available")
Enable of the traversing direction

The retraction can be limited to the positive direction of travel or enabled for both travel
directions:
MD10735 $MN_JOG_MODE_MASK, Bit 8

Value Meaning
0 Traversing enable: Only plus direction
1 Traversing enable: Plus and minus direction
Axial machine data
Measuring system status

The current status of the measuring system is displayed via the machine data, or must be
set in preparation for the required behavior:
MD34210 $MA_ENC_REFP_STATE[<axis>]
Value Meaning
1)
Absolute encoder
2 Encoder is calibrated
Incremental encoder
1 Automatic referencing: Enabled, but encoder still not referenced
2 Automatic referencing: Encoder is referenced and in exact stop, automatic referencing takes
effect at next time encoder activation
3 Restoration of the actual position: The last axis position buffered before switching off is
restored, no automatic referencing
1) Only values relevant for JOG retract
Extended Functions
3.9.3 Selection
Function
Requirement
The selection of JOG retract is only possible, if valid retraction data is available for the
relevant channel, the channel is in JOG mode and in the "Reset" state:
DB21, ... DBX377.5 == 1 (retraction data available)
DB11, ... DBX(n*20+6).2 == 1 (active mode: JOG, with n=0, 1 ,2 ... for mode group 1, 2,
...)
DB21, DBX35.7 == 1 (channel state: Reset).
Axes and spindles

All active measuring systems of the machine axes involved in the retraction in the tool
direction must be in the "referenced" or "restored" state when the control is switched on
again (Power On).
A detailed description of the automatic restoration of actual positions after the next start of
the control (Power On) can be found in:
References:
Basic Functions Function Manual, Section "R1 Referencing" > "Automatic restoration of the
machine reference"
Axis interchange
If all the axes and spindles involved in the retraction are not assigned to the channel at the
time of selection, an implicit axis interchange is performed for the missing axes.
Coordinate system
With the selection of JOG retract, the workpiece coordinate system (WCS) is set for the
traversing of the channel axes. Axes involved in the retraction can only be traversed in the
WCS. All axes that are not involved in the retraction can also be traversed in the machine
coordinate system (MCS).
Selection options
The selection of JOG retract can be supported through automatic selection of the JOG mode
after Power On. The actual selection of JOG retract is then performed through manual
selection via the user interface or via the PLC user program.
Automatic selection of JOG mode

If retraction data is available for a channel, JOG mode is selected for the mode group after
the control runs up. The parameter assignment is performed via machine data MD10721
$MN_OPERATING_MODE_EXTENDED. See Section "Parameter assignment (Page 191)".
Extended Functions
Selection via the user interface

The selection of JOG retract is performed on the user interface via the "Retract" softkey:
"Machine operating area" > "ETC key (">")" > "Retract"
Selection by PLC user program

The following actions must be performed to select JOG retract by the PLC user program:
Channel-specific query whether retraction data is available
DB21, DBX377.5 == 1 (retraction data available)
Mode group-specific selection of JOG mode:
DB11, ... DBX(n*20+6).2 == 1 (active mode: JOG, with n=0, 1 ,2 ... for mode group 1, 2,
...)
Channel-specific selection of JOG retract via the PI service "RETRAC".
A detailed description of the activation of the PI service "RETRAC" via the function block
FB 4 can be found in:
References:
Basic functions Function Manual, Section "P3: Basic PLC program for SINUMERIK 840D
sl" > "PI services"
After confirmation of the selection of JOG retract (see below), select the workpiece
coordinate system:
DB19.DBX20.7 (switch MCS/WCS)
DB19.DBX0.7 (actual value 1 =WCS, 0 =MCS)
Selection confirmation
Following a successful selection, the following NC/PLC interface signal is set:
DB21, ... DBX377.4 = 1 (JOG retract active)
Thread cutting (G33 or G331/G332)

If the program execution was aborted during a thread cutting operation (G33 or G331/G332), the
axis grouping of tool axis and spindle is restored when JOG retract is selected. The
controller parameters and parameter sets for the involved axes are also set in accordance
with a programmed thread cutting in the part program.
Extended Functions
3.9.4 Tool retraction
General retraction behavior

The tool is retracted by manually traversing the geometry axis specified when selecting JOG
retract in the workpiece coordinate system (WCS). The specification of the retraction
movement can be performed via the traversing keys of the machine control panel (MCP) or
via the handwheel. Retraction is possible within the traversing range limits (working area
limitation, software limit switch, etc.).
The retraction movement can be stopped and started again with NC stop and NC start.
The axes and spindles not involved in the tool retraction can be manually traversed as
required.
Traversing direction
Per default, the retraction movement is only enabled for the positive traversing direction. If
traversing in the negative direction is also to be possible, this must be explicitly enabled:
MD10735 $MN_JOG_MODE_MASK, Bit 8
Retraction behavior for thread cutting (G33) or tapping (G331, G332)

In addition to the geometry axes, a spindle is also involved in the retraction movement for
thread cutting (G33 or G331/G332). The retraction movement is executed when either the
selected geometry axis or the spindle is traversed.
Retraction using the handwheel

If one of the axes involved in the retraction movement is traversed by means of traversing
key, the handwheel pulses for other axes involved in the retraction movement are ignored.
If handwheels have been selected for several axes and these are moved, the handwheel
pulses are evaluated in the following order:
1. Retraction axis
2. Spindle
3. Axes/spindles not involved in the retraction movement
The pulses of the other handwheels are ignored and only evaluated at standstill of the
preceding handwheels.
Locked functions
During JOG retract, the requirements for the following functions are ignored:
Spindle start via DB31, ... DBX30
Traversing of a spindle or axis involved in the retraction via function block FC18
Switchover of a spindle or an axis involved in the retraction to the PLC-controlled axis
Changing a spindle or axis involved in the retraction to another channel
Using a spindle or axis involved in the retraction as main run axis (command axis,
oscillating axis, FC18 / concurrent axis)
Extended Functions
3.9.5 Deselection
JOG retract is deselected channel-specifically via:
Channel reset
Machine control panel: "Reset" button
Basic PLC program: DB21, DBX7.7 = 1 (reset)
User interface: "Back" ("<<") softkey
This activates the initial settings via the following machine data:
MD20110 $MC_RESET_MODE_MASK[<channel>] ()
MD20150 $MC_GCODE_RESET_VALUES[<channel>] ()
MD20151 $MC_GCODE_RESET_MODE[<channel>] ()
After the deselection, the channel is in the JOG mode in the channel state "Reset".
All channel axes can now be traversed manually in JOG mode. The retraction data is
retained. It is therefore possible to select JOG retract again.
NC/PLC interface signal

With the deselection of JOG retract, the NC/PLC interface signal is reset:
DB21, ... DBX377.4 = 0 (JOG retract active)
3.9.6 Repeated selection

JOG retract can continue to be selected as long as retraction data is available:
DB21, ... DBX377.5 == 1 (retraction data available)
If selected again, the original retraction data is restored. In each case, a different geometry
axis can be specified as retraction axis.
Changed axis positions

The channel axes can be traversed in JOG mode while JOG retract is deselected. If JOG
retract is selected again, the retraction movement is executed on the basis of the new axis
positions.
Extended Functions
3.9.7 Continuing machining
AUTOMATIC mode
Before the aborted part program is continued with NC start in AUTOMATIC mode, all
machine axes with active measuring systems in the state "restored" or "not referenced" must
be referenced.
NOTICE
Possible axis position displacement
After the control runs up after a power failure, the axis positions for incremental measuring
systems are synchronized or restored corresponding to the setting in machine data. Once
the tool has been retracted in JOG retract submode, axes whose positions have been
restored are referenced.
MDI mode and overstore

In the MDI mode and for the overstore function, machining can also be performed, without
referencing the axes, with restored positions. To do this, NC start with restored positions
must be enabled explicitly for a specific channel:
MD20700 $MC_REFP_NC_START_LOCK = 2
Block search at interruption point

The processing of the part program can be continued from the interruption point via a block
search at the interruption point. The last block of the main program level before the
interruption is available as interruption point.
A detailed description of the function and for the operation of the block search can be found
in:
References
Basic Functions Function Manual; Section "K1: Mode group, channel, program operation,
reset response" > "Block search" or "Block search type 5 SERUPRO"
Turning or Milling Operating Manual; Section "Workpiece machining" > "Starting machining
at a specific point"
Continue with NC start

With NC start in the AUTOMATIC or MDI mode, the processing of the part program is
continued from the selected position. The following actions are performed with regard to
JOG retract:
The retraction data is deleted.
The NC/PLC interface signal is reset:
DB21, DBX377.5 = 0 (retraction data available)
The current data environment is saved.
Extended Functions
3.9.8 State diagram
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Figure 3-6 State diagram: JOG retract
3.9.9 System data

The following system data is available for JOG retract:
Meaning System variable $VA_ NC/PLC interface OPI variable

Retraction data available - DB21, ... DBX377.5 retractState, bit 0
JOG retract active - DB21, ... DBX377.4 retractState, bit 1
Retraction axis - - retractState, bits 2 - 3
Position restored, 1st measuring system $AA_POSRES DB31, ... DBX71.4 aaPosRes
Position restored, 2nd measuring system $AA_POSRES DB31, ... DBX71.5 aaPosRes
References
OPI and system variable

Lists Book 2 List Manual, Section "Variables".
Extended Functions
Incremental measuring systems

The user must ensure that machine axes with incremental measuring systems are clamped
with sufficient speed in the event of a power failure to prevent a change to the last position,
known and saved by the control. Otherwise the assumed position when the control is
restarted differs greatly to the actual position of the machine axis. Drive-autonomous
retraction must also not be activated for these axes.
A detailed description of the automatic restoration of actual positions after the next start of
the control (Power On) can be found in:
References:
Basic Functions Function Manual, Section "R1 Referencing" > "Automatic restoration of the
machine reference"
Drive-autonomous retraction
The "Drive-autonomous retraction" function must not be activated for machine axes involved
in the retraction movement.
Axis couplings
Axis couplings are not restored with the selection of JOG retract.
Tapping using G63

JOG retract is not possible for tapping with compensating chuck and speed-controlled
spindle without encoder (G63).
Transformations
If a transformation is selected through JOG retract, the active measuring systems of all
machine axes involved in the transformation must be in the "referenced" or "restored" state.
OEM transformations such as parallel kinematics for hexapods, can only be traversed with
referenced measuring systems. Traversing with restored axis positions is not possible.
Tool orientation via directly programmed orientation axes

JOG retract cannot generate a retraction movement in the tool direction if the tool orientation
is not performed via NC functions, but through direct programming of the orientation axes.
NCU link
JOG retract is also possible in conjunction with NCU-wide traversing of axes (see Section
"NCU link (Page 79)"). The state of axis containers is not changed through JOG retract.
Adaptations required for a retraction movement in the tool direction must be performed by
the user before traversing in JOG retract, e.g. in the MDI mode.
Extended Functions
3.10 Start-up: Handwheels
3.10.1 General information

In order to operate handwheels of a SINUMERIK control system, they have to be
parameterized via NCK machine data.
If the handwheels are not directly connected to the control, additional measures are required,
e.g. connection via PROFIBUS- or Ethernet-MCP or handwheel module, inserting and
configuring the module with SIMATIC STEP 7, HW-Config.
Note
Currently only six handwheels can be parameterized in a SINUMERIK control system.
Connection options
SINUMERIK 840D sl
For SINUMERIK 840D sl, handwheels can be connected via the following components:
PROFIBUS (Page 203) module
Ethernet (Page 206) module
Note
Several handwheels, which are connected via different components, can be connected to
one SINUMERIK 840D sl at the same time.
SINUMERIK 828D
For SINUMERIK 828D, handwheels can be connected via the following components:
PPU (Page 201)
Machine control panel (MCP) via PROFIBUS (Page 202)
Note
Several handwheels, which are connected via different components, can be connected to
one SINUMERIK 828D at the same time.
Extended Functions
3.10.2 Connection via PPU (only 828D)
Handwheels directly connected to terminal X143 of the PPU are parameterized using the
following NCK machine data:
MD11350 $MN_HANDWHEEL_SEGMENT[<Handwheel_No._in_NCK - 1>] = 2
When directly connected to the PPU, a 2 (8xxD_HW) must always be entered as
handwheel segment.
MD11351 $MN_HANDWHEEL_MODULE[< Handwheel_No._in_NCK - 1 >] = 1
When directly connected to the PPU, a 1 must always be entered.
MD11352 $MN_HANDWHEEL_INPUT[< Handwheel_No_in_NCK - 1 >] = <Handwheel
connection >
The number of the handwheel has to be entered: 1 or 2
Note
Two handwheels can be connected to a PPU (terminal X143).
Example
Parameter assignment of two handwheels connected via terminal X143 of the PPU.
Machine data Value Meaning
1st handwheel:
MD11350 $MN_HANDWHEEL_SEGMENT[0] 2 Hardware segment: 8xxD_HW
MD11351 $MN_HANDWHEEL_MODULE[0] 1 ---
MD11352 $MN_HANDWHEEL_INPUT[0] 1 1st handwheel connection of X143
2nd handwheel:
MD11352 $MN_HANDWHEEL_INPUT[1] 2 2nd handwheel connection of X143
Extended Functions
3.10.3 Connection via PROFIBUS (828D)
For the SINUMERIK 828D, in addition to the connection of two handwheels to the PPU
interface, terminal X143, a third handwheel can also be connected via a machine control
panel, e.g. MCP 483C PN, interface X60.
The parameter assignment of the third handwheel is performed in the following NCK
machine data:
MD11350 $MN_HANDWHEEL_SEGMENT[ 2 ] = 5
MD11351 $MN_HANDWHEEL_MODULE[ 2 ] = 1
MD11352 $MN_HANDWHEEL_INPUT[ 2 ] = 1
Requirement
Operation of the control with default data (machine data, STEP 7 configuration).
Example
Parameterization of three handwheels, connected via PPU and an "MCP 483C PN" machine
control panel.
Handwheel number Machine data set Connection

in NCK (Index)
1 0 PPU, 1st handwheel in the handwheel slot
2 1 PPU, 2nd handwheel in the handwheel slot
3 2 MCP, 1st handwheel in the handwheel slot
Parameterizing in the NCK machine data:
1st handwheel in the NCK

MD11352 $MN_HANDWHEEL_INPUT[0] 1 1st handwheel in the handwheel slot
2nd handwheel in the NCK

MD11352 $MN_HANDWHEEL_INPUT[1] 2 2nd handwheel in the handwheel slot
3rd handwheel in the NCK

MD11350 $MN_HANDWHEEL_SEGMENT[2] 5 Hardware segment: PROFIBUS
MD11351 $MN_HANDWHEEL_MODULE[2] 1 Reference to logical base address of the handwheel slot of
the MCP
Extended Functions
3.10.4 Connection via PROFIBUS (840D sl)
The parameter assignment of handwheels connected via PROFIBUSmodules (e.g.
"MCP 483" machine control table) is performed with the following NCK machine data:
MD11350 $MN_HANDWHEEL_SEGMENT[<Handwheel_No._in_NCK - 1>] = 5
When connected via PROFIBUSmodule, the hardware segment has always to be entered
as 5 (PROFIBUS).
MD11351 $MN_HANDWHEEL_MODULE[<Handwheel_No._in_NCK - 1>] = <Index + 1>
The reference to the MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS[<Index>]
has to be entered, which contains the logical base address of the handwheel.
MD11352 $MN_HANDWHEEL_INPUT[<Handwheel_No._in_NCK - 1>] =
<Number_in_handwheel_slot>
A handwheel slot can contain several handwheels. The number of the handwheel within
the handwheel slot has to entered: 1, 2, ...
MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS[<Index>] = <logical base address>
The logical base address of the handwheel slot, specified in SIMATIC STEP 7, HW
Config, has to be entered.
Handwheel slot
The PROFIBUSmodule must be configured besides the parameterization of handwheels in
the NCK machine data in STEP 7. Among others the logical address of the handwheel slot is
specified.
The handwheel slot is situated at the following slot of the PROFIBUSmodule:
PROFIBUS module Slot

Machine control panel MCP 483 2
Machine control panel MCP 310 2
Handwheel connection module 1
Example
Parameterization of five handwheels, connected via four machine control tables "MCP 483".
Two handwheels can be connected to a machine control table "MCP 483".

in NCK (Index)
1 0 1st MCP, 1st handwheel in handwheel slot
2 1 1st MCP, 2nd handwheel in the handwheel slot
Extended Functions

in NCK (Index)
3 2 2nd MCP, 1st handwheel in the handwheel slot
5 4 3rd MCP, 1st handwheel in the handwheel slot
6 5 4th MCP, 2nd handwheel in the handwheel slot
The 4th handwheel in the NCK is not used (gap in machine data).
Note
Machine data gaps are allowed when parameterizing handwheels in NCK machine data.
Machine control tables have been configured in SIMATIC STEP 7, HW Config as follows:
Slot DP ID Order No. / Description I address O address

...
1st MCP 1 55 Standard+Handwheel 0 ... 7 0 ... 7
2 2AE standard+handwheel 288 ... 291
3 1 standard+handwheel
2nd MCP 1 55 Standard+Handwheel 8 ... 15 8 ... 15
3rd MCP 1 55 Standard+Handwheel 16 ... 23 16 ... 23
4th MCP 1 55 Standard+Handwheel 24 ... 29 24 ... 29
Parameterizing in the NCK machine data:
1st handwheel in the NCK

the 1st MCP
2nd handwheel in the NCK

the 1st MCP
Extended Functions
3rd handwheel in the NCK

the 2nd MCP
4th handwheel in the NCK

MD11350 $MN_HANDWHEEL_SEGMENT[3] 0 No handwheel parameterized
MD11351 $MN_HANDWHEEL_MODULE[3] 0 No handwheel parameterized
MD11352 $MN_HANDWHEEL_INPUT[3] 0 No handwheel parameterized

the 3rd MCP

the 4th MCP
Logical base addresses:

MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [0] 288 Logical base address handwheel slot 1st MCP
MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [1] 304 Logical base address handwheel slot 2nd MCP
MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [4] 330 Logical base address handwheel slot 4th MCP
MD11353 $MN_HANDWHEEL_LOGIC_ADDRESS [5] 320 Logical base address handwheel slot 3rd MCP
Extended Functions
3.10.5 Connected via Ethernet (only 840D sl)
Parameter setting
The parameters for handwheels connected via Ethernet modules, e.g. machine control panel
"MCP 483C IE", "HT 8", or "HT 2", are assigned in the following NC machine data:
MD11350 $MN_HANDWHEEL_SEGMENT[< x - 1 >] = 7
When connected via Ethernet modules, the segment always has to be entered as 7
(Ethernet).
MD11351 $MN_HANDWHEEL_MODULE[< x - 1 >] = 1
When connected via Ethernet modules, the module always has to be entered as 1.
MD11352 $MN_HANDWHEEL_INPUT[< x - 1 >] = y
where y = 1, 2, 3, etc. (handwheel interface at the Ethernet bus)
where x = 1, 2, 3, etc. (handwheel number in the NC)
Handwheel interfaces at the Ethernet Bus

The handwheel interfaces at the Ethernet bus are numbered on the basis of the following
considerations:
The sequence of the operator component interfaces is: MCP1, MCP2, BHG
Each operator component interface has two handwheel interfaces
Operator components: MCP 483C IE
A maximum of two handwheels can be connected to an MCP 483C IE via connections
X60 and X61 . The assignment of the connections in the operator component interface is:
Connection X60: 1st handwheel in operator component interface MCP1 /MCP2
Connection X61: 2nd handwheel in operator component interface MCP1 /MCP2
Operator components: HT 8
The handwheel of the HT 8 is always assigned to the 1st handwheel of operator
component interface MCP1 /MCP2 .
Operator components: HT 2
The handwheel of the HT 2 is always assigned to the 1st handwheel of operator
component interface BHG .
Extended Functions
Operator component interface -> MCP1 MCP2 BHG

Handwheel interface 1) 1 2 1 2 1 2
FB1 parameters 2) MCP1BusAdr MCP2BusAdr BHGRecGDNo
Assignment of the handwheels 3)
MCP 483C IE X60 X61 X60 X61 - -

HT 8 x - x - - -
HT 2 - - - - x -
Handwheel interface at the Ethernet bus (y) 4) - 1 2 3 4 5 6
>
1) Numbering of the handwheel interfaces within an operator component interface
2) Assignment of the operator component to the interface via the corresponding FB1 parameter
3) Assignment of the handwheels of the respective operator components to the handwheel interfaces
4) Numbering of the handwheel interfaces at the Ethernet bus -> MD11352 $MN_HANDWHEEL_INPUT[< x - 1 >] = y
Example
Parameterization of 3 handwheels, connected via the following operator components:
Operator component interface -> MCP1 MCP2 BHG

Operator component HT 8 MCP 483C HT 2
FB1 parameters MCP1BusAdr := 39 MCP2BusAdr := 192 BHGRecGDNo := 40
Handwheel interface x - - X61 x -
Handwheel interface at Ethernet Bus -> 1 2 3 4 5 6
Table 3- 1 NCK machine data for the handwheel assignment
Machine data Value Description

HT 8: Handwheel number in the NC = 1
MD11350 $MN_HANDWHEEL_SEGMENT[ 0 ] 7 Segment: Ethernet
MD11350 $MN_HANDWHEEL_MODULE[ 0 ] 1 Module: Ethernet
MD11350 $MN_HANDWHEEL_INPUT[ 0 ] 1 Handwheel interface at Ethernet bus
MCP 483C IE: Handwheel number in the NC = 2
MD11350 $MN_HANDWHEEL_ MODULE [ 1 ] 1 Module: Ethernet
MD11350 $MN_HANDWHEEL_ INPUT [ 1 ] 4 Handwheel interface at Ethernet bus
HT 2: Handwheel number in the NC = 3
MD11350 $MN_HANDWHEEL_ MODULE [ 2 ] 1 Module: Ethernet
MD11350 $MN_HANDWHEEL_ INPUT [ 2 ] 5 Handwheel interface at Ethernet bus
Extended Functions
Table 3- 2 FB1 parameters (excerpt)
Parameter Value Remark

MCPNum := 2 // Number of connected MCP
// MCP1 = HT 8
MCP1In ... // MCP1-Parameter ...
... ...
MCP1BusAdr := 39 // Via switches S1 and S2 on the connecting device
// set "IP address"
// MCP2 = MCP 483C IE
MCP2In ... // MCP2-Parameter ...
... ...
MCP2BusAdr := 192 // Via switch S2 on the MCP 483C
// set "IP address"
MCPBusType := b#16#55 // Bus type: Ethernet
// HHU = HT 2
HHU := 5 // Bus type: Ethernet
HHUIn ... // HHU Parameter ...
... ...
HHURecGDNo := 40 // Via switches S1 and S2 on the connecting device
// set "IP address"
Filter time
Since the handwheel pulses on the Ethernet bus are not transferred deterministically,
filtering (smoothing) of the handwheel pulse transfer process may be necessary for highly
dynamic drives. The parameter for the filter time is assigned using the following machine
data:
MD11354 $MN_HANDWHEEL_FILTER_TIME[< x - 1 >] = <filter time>
where x = 1, 2, 3, etc. (handwheel number in the NC) and filter time = 0.0 to 2.0 s
The filter time specifies the time it takes for the handwheel pulses transferred to the control
to be sent on to the interpolator for traversing purposes. With a filter time of 0.0 s, the
handwheel pulses are sent on to the interpolator within a single interpolation cycle. This can
result in the relevant axis being traversed jerkily.
The recommended filter time is 0.2 to 0.5 s.
Extended Functions
3.11 Special features relating to manual and handwheel travel
Stationary state detection

A stationary state is detected by the Ethernet modules to which the handwheel is connected.
If a handwheel does not transfer any handwheel pulses for a defined period of time, the
module detects this to be a stationary state and transfers it to the NC/PLC interface:
NC/PLC interface signal Value Description

DB10, DBX245.0 0 Handwheel 1 is operated
1 Handwheel 1 is stationary
By evaluating the signal, it is possible to reduce the overtravel of an axis traversed via the
handwheel, due to the handwheel pulses that have been collected in the control but not yet
transferred to the interpolator for traversing purposes. To do this, deletion of the distance-to-
go must be triggered for the relevant axis or in the channel when a stationary state is
detected:
DB31,... DBX2.2 = 1 (axial deletion of distance-to-go)
DB21,... DBX6.2 = 1 (channel-spec. deletion of distance-to-go)
3.11.1 Manual travel of geometry/orientation axes
Coordinate systems in JOG

In JOG mode, the user can also traverse the axes declared as geometry axes in the
workpiece coordinate system manually. Any coordinate offsets or rotations that have been
selected remain active.
Note
In the JOG mode, using the "Handling transformation package" for SINUMERIK 840D sl, the
translation of geometry axes in several valid references systems can be set separately from
one another.
Reference:
Function Manual, Special Functions; Multi-Axis Transformations (F2), Section: "Cartesian
manual travel"
Extended Functions
Application
Manual movements for which transformations and frames have to be active. The geometry
axes are traversed in the most recently valid coordinate system. The special features of
geometry-axis manual travel are described below.
Simultaneous travel
Only one geometry axis can be traversed continuously or incrementally at one time using the
traversing keys. Where an attempt is made to traverse more than one geometry axis, alarm
20062 "Axis already active" is output. However, three geometry axes can be traversed
simultaneously using handwheels 1 to 3. Alarm 20060 is output if only one axis is not defined
as a geometry axis.
PLC interface
For geometry/orientation axes, there is a separate PLC interface that contains the same
signals as the axis-specific PLC interface:
Geometry axes:
DB21, ... DBB12-23 and
DB21, ... DBB40-56
Orientation axes:
DB21, ... DBB320-331 and
DB21, ... DBB332-343
Feedrate/rapid traverse override

The channel-specific feedrate-override switch and rapid-traverse-override switch are active
for geometry-axis manual travel in rapid traverse override.
Acceleration and jerk

For the manual travel of geometry axes/orientation, the acceleration and jerk can be limited
for specific channels. This enables better handling of the kinematics that generate Cartesian
motions entirely via rotary axes (robots).
Geometry axes
The maximum acceleration when manually traversing geometry axes can be specified for
each channel via the machine data:
MD21166 $MC_JOG_ACCEL_GEO [<geometry axis>]
With <geometry axis> = 0, 1, 2
The maximum jerk when manually traversing geometry axes in the SOFT acceleration mode
(acceleration with jerk limitation) can be specified for each channel via the machine data:
MD21168 $MC_JOG_JERK_GEO [<geometry axis>]
With <geometry axis> = 0, 1, 2
Extended Functions
Orientation axes
The maximum jerk when manually traversing orientation axes can be specified for each
channel via the machine data:
MD21158 $MC_JOG_JERK_ORI [<orientation axis>]
For MD21158 to take effect, the channel-specific jerk limitation for the manual traversing of
orientation axes must be enabled via the following machine data:
MD21159 $MC_JOG_JERK_ORI_ENABLE == TRUE
Reference:
Alarms
Alarm 20062, "Axis already active", is triggered in the case that a geometry axis/orientation
axis is manually traversed under the following conditions:
The axis is already being traversed in JOG mode via the axial PLC interface.
A frame for a rotated coordinate system is already active and another geometry axis in
this coordinate system is traversed in JOG mode with the traversing keys.
If the axis is not defined as a geometry axis, alarm 20060, "Axis cannot be traversed as a
geometry axis", is output if you attempt to traverse it as a geometry axis in JOG mode.
3.11.2 Spindle manual travel
Spindle manual travel

Spindles can also be traversed manually in JOG mode. Essentially, the same conditions
apply as for manual travel of axes. Spindles can be traversed in JOG mode using the
traversing keys continuously or incrementally, in jog or continuous mode, or using the
handwheel. The function is selected and activated via the axis-/spindle-specific PLC
interface in the same way as for the machine axes. The axis-specific machine data also
apply to the spindles.
Spindle mode
Spindle manual travel is possible in positioning mode (spindle is in position control) or in
open-loop control mode.
Extended Functions
JOG velocity
The velocity used for spindle manual travel can be defined as follows:
Using general setting data
SD41200 $SN_JOG_SPIND_SET_VELO (speed of spindle in JOG mode), which is valid
for all spindles
or
Using machine data
MD32020 $_MA_JOG_VELO (JOG axis velocity)
However, the machine data is only effective if
SD41110 $SN_JOG_SET_VELO (axis velocity in JOG) = 0.
The maximum speeds for the active gear stage also apply when spindles are traversed in
JOG mode.
References:
Function Manual Basic Functions; Spindles (S1)
Velocity override
The spindle-override-switch JOG velocity is active for spindles.
JOG acceleration
As a spindle often uses many gear stages in speed-control and position-control modes, the
acceleration associated with the current gear stage is always applied to the spindle in JOG
mode.
References:
PLC interface signals

In the case of spindle manual travel, the PLC interface signals between the NCK and PLC
have the same effect as for machine axes.
Interface signals
DB31, ... DBX60.7 or DBX60.6 (position reached with fine or coarse exact stop)
are only set if the spindle is in position control.
In the case of interface signals that are only spindle-specific, while the spindles are
traversing in JOG the following should be noted:
The following PLC interface signals to the spindle have no effect:
DB31, ... DBX17.6 (invert M3/M4)
DB31, ... DBX18.6/7 (oscillation rotation direction right/left)
DB31, ... DBX18.5 (oscillation enable)
DB31, ... DBX16.7 (delete S value)
The following PLC interface signals from the spindle are not set:
DB31, ... DBX83.7 (clockwise actual direction of rotation)
DB31, ... DBX83.5 (spindle in set range)
Extended Functions
3.11.3 Monitoring functions
Limitations
The following limitations are active for manual and handwheel travel:
Working-area limitation (axis must be referenced)
Software limit switches 1 and 2 (axis must be referenced)
Hardware limit switches
The control ensures that the traversing movement is aborted as soon as the first valid
limitation has been reached. Velocity control ensures that deceleration is initiated early
enough for the axis to stop exactly at the limit position (e.g. software limit switch). Only when
the hardware limit switch is triggered does the axis stop abruptly with "rapid stop".
Alarms are triggered when the various limitations are reached (alarms 16016, 16017, 16020,
16021). The control automatically prevents further movement in this direction. The traversing
keys and the handwheel have no effect in this direction.
Note
The software limit switches and working-area limitations are only active if the axis has first
been referenced.
If a work offset (DRF offset) via handwheel is active for axes, the software limit switches for
these axes are monitored during the main run in JOG mode. This means that the jerk
limitation has no effect when the software limit switches are approached. After acceleration
in accordance with MD32300 $MA_MAX_AX_ACCEL (maximum axis acceleration) the
velocity is reduced at the software limit switch.
For further information on working area limitations and hardware and software limit switches,
see:
References:
Function Manual, Axis Monitoring, Protection Zones (A3)
Retract axis
The axis can be retracted from a limit position by moving it in the opposite direction.
Note
Machine manufacturer
The function for retracting an axis that has approached the limit position depends on the
machine manufacturer. Please refer to the machine manufacturer's documentation!
Extended Functions
Maximum velocity and acceleration

The velocity and acceleration used during manual travel are defined by the startup engineer
for specific axes using machine data. The control limits the values acting on the axes to the
maximum velocity and acceleration specifications.
References:
Function Manual Basic Functions; Velocities, Setpoint/Actual Value Systems, Closed-Loop
Controls (G2)
Function Manual Basic Functions; Acceleration (B2)
3.11.4 Other
Mode change from JOG to AUTO or from JOG to MDI

It is only possible to switch operating modes from JOG to AUTO or MDI if all axes in the
channel have reached "coarse exact stop".
References:
Response (K1)
Rotational feedrate active in JOG

In JOG mode, it is also possible to traverse an axis manually at a revolutional feedrate (as
for G95) specific to the current speed of the master spindle.
This is activated using the setting data:
SD41100$SN_JOG_REV_IS_ACTIVE (JOG: Revolutional/linear feedrate)
The feedrate value (in mm/rev) used can be defined as follows:
with the general setting data:
SD41120 $SN_JOG_REV_SET_VELO (revolutional feed of axes in JOG)
using the axial machine data:
MD32050 $MA_JOG_REV_VELO (revolutional feed rate for JOG mode)
or for rapid traverse override:
MD32040 $MA_JOG_REV_VELO_RAPID (revolutional feedrate for JOG with rapid
traverse override), if SD41120 = 0.
If a master spindle has not been defined and the axis is to be traversed in JOG at a
revolutional feedrate, alarm 20055 is output (alarm 20065 for geometry axes).
Extended Functions
3.12 Data lists
Transverse axes
If a geometry axis is defined as transverse axis:
MD20100 $MC_DIAMETER_AX_DEF (geometry axes with transverse axis function)
and radius programming has been selected, when traversing in JOG, the following features
should be carefully observed:
Continuous travel:
There are no differences when a transverse axis is traversed continuously.
Incremental travel:
Only half the distance of the selected increment size is traversed. For example, with
INC10 the axis only traverses 5 increments when the traversing key is pressed.
Traversing with the handwheel:
As for incremental travel, with the handwheel only half the distance is traversed per
handwheel pulse.
References:
Function Manual Basic Functions; Transverse Axes (P1)
3.12 Data lists
3.12.1 Machine data

10000 AXCONF_MACHAX_NAME_TAB[n] Machine axis name
10720 OPERATING_MODE_DEFAULT Setting of the operating mode after Power On
10721 OPERATING_MODE_EXTENDED Extended setting of the operating mode after Power On
10735 JOG_MODE_MASK Settings for JOG mode
11300 JOG_INC_MODE_LEVELTRIGGRD INC and REF in inching mode
11310 HANDWH_REVERSE Defines movement in the opposite direction
11320 HANDWH_IMP_PER_LATCH[n] Handwheel pulses per locking position
11324 HANDWH_VDI_REPRESENTATION Coding of the handwheel number (NCK/PLC interface)
11330 JOG_INCR_SIZE_TAB[n] Increment size for INC/handwheel
11340 ENC_HANDWHEEL_SEGMENT_NR Third handwheel: Bus segment
11342 ENC_HANDWHEEL_MODULE_NR Third handwheel: Logical drive number
11344 ENC_HANDWHEEL_INPUT_NR Third handwheel: Encoder interface
11346 HANDWH_TRUE_DISTANCE Handwheel path or velocity specification
11350 HANDWHEEL_SEGMENT[n] Handwheel segment
Extended Functions
3.12 Data lists

11351 HANDWHEEL_MODULE[n] Handwheel module
11352 HANDWHEEL_INPUT[n] Handwheel connection
11353 HANDWHEEL_LOGIC_ADDRESS[n] Logical handwheel slot address (STEP 7)
17900 VDI_FUNCTION_MASK Function mask for VDI signals
3.12.1.2 Channel-specific machine data

20060 AXCONF_GEOAX_NAME_TAB Geometry axis in channel
20100 DIAMETER_AX_DEF Geometry axes with transverse axis functions
20110 RESET_MODE_MASK Initial setting after reset / program end
20150 GCODE_RESET_VALUES Reset position of the G groups
20151 GCODE_RESET_MODE Reset behavior of the G groups
20360 TOOL_PARAMETER_DEF_MASK Definition of the tool parameters
20620 HANDWH_GEOAX_MAX_INCR_SIZE Limitation of the geometry axes
20622 HANDWH_GEOAX_MAX_INCR_VSIZE Path-velocity override
20624 HANDWH_CHAN_STOP_COND Definition of the behavior of traveling with handwheel,
channel-specific
20700 REFP_NC_START_LOCK NC start disable without reference point
21150 JOG_VELO_RAPID_ORI Conventional rapid traverse for orientation axes
21158 JOG_JERK_ORI Maximum jerk when manually traversing orientation
axes
21159 JOG_JERK_ORI_ENABLE Jerk limitation for manual travel of orientation axes
enabled
21165 JOG_VELO_GEO Conventional speed for geometry axes
21166 JOG_ACCEL_GEO Maximum acceleration when manually traversing
geometry axes
21168 JOG_JERK_GEO Maximum jerk when manually traversing geometry
axes

30450 IS_CONCURRENT_POS_AX Default setting at reset: Neutral axis or channel axis
30600 FIX_POINT_POS[n] Fixed point positions of the axis
30610 NUM_FIX_POINT_POS Number of fixed point positions of an axis
31090 JOG_INCR_WEIGHT Weighting of an increment for INC/handwheel
32000 MAX_AX_VELO Maximum axis velocity
32010 JOG_VELO_RAPID Rapid traverse in jog mode
Extended Functions
3.12 Data lists

32020 JOG_VELO Conventional axis velocity
32040 JOG_REV_VELO_RAPID Revolutional feedrate in JOG mode with rapid traverse
override
32050 JOG_REV_VELO Revolutional feedrate for JOG
32060 POS_AX_VELO Reset position for positioning-axis velocity
32080 HANDWH_MAX_INCR_SIZE Limitation of the selected increment size
32082 HANDWH_MAX_INCR_VELO_SIZE Limitation of the selected increment for velocity override
32084 HANDWH_STOP_COND Behavior, handwheel travel
32090 HANDWH_VELO_OVERLAY_FACTOR Ratio of JOG velocity to handwheel velocity (with DRF)
32300 MAX_AX_ACCEL Maximum axis acceleration
32301 JOG_MAX_ACCEL Maximum axial acceleration for JOG movements
32420 JOG_AND_POS_JERK_ENABLE Initial setting for axial jerk limitation
32430 JOG_AND_POS_MAX_JERK Maximum axial jerk for single axis movements
32431 MAX_AX_JERK Maximum axial jerk for path movements
32436 JOG_MAX_JERK Maximum axial jerk for JOG movements
34210 ENC_REFP_STATE Measuring system status
35130 GEAR_STEP_MAX_VELO_LIMIT[n] Maximum velocity for gear stage
3.12.2 Setting data

41010 JOG_VAR_INCR_SIZE Size of variable increment for INC/handwheel
41050 JOG_CONT_MODE_LEVELTRIGGRD JOG continuous in inching mode
41100 JOG_REV_IS_ACTIVE Revolutional feedrate in JOG mode active
41110 JOG_SET_VELO JOG velocity for linear axes (for G94)
41120 JOG_REV_SET_VELO JOG velocity (for G95)
41130 JOG_ROT_AX_SET_VELO JOG velocity for rotary axes
41200 JOG_SPIND_SET_VELO JOG velocity for the spindle
Extended Functions
3.12 Data lists
3.12.3 Signals

Handwheel 1 is operated DB10.DBB68 DB2700.DBB12
Handwheel 2 is operated DB10.DBB69 DB2700.DBB13
Handwheel 3 is operated DB10.DBB70 -
Ethernet handwheel is stationary DB10.DBB245 -
3.12.3.2 Signals to mode group

Mode Group1: JOG mode DB11.DBX0.2 DB3000.DBX0.2
Mode group2: JOG mode DB11.DBX20.2 -
3.12.3.3 Signals from mode group

Mode Group1: Active mode JOG DB11.DBX6.2 DB3100.DBX0.2
Mode group2: Active mode JOG DB11.DBX26.2 -
Extended Functions
3.12 Data lists

3.12.3.4 Signals to channel

Activate DRF DB21, ... .DBX0.3 DB3200.DBX0.3
Geometry axis 1: Activate handwheel DB21, ... .DBX12.0-2 DB3200.DBX1000.0-2
Geometry axis 1: Traversing key lock DB21, ... .DBX12.4 DB3200.DBX1000.4
Geometry axis 1: Rapid traverse override DB21, ... .DBX12.5 DB3200.DBX1000.5
Geometry axis 1: Traversing keys minus/plus DB21, ... .DBX12.6-7 DB3200.DBX1000.6-7
Geometry axis 1: Machine function 1 INC ... Var. INC DB21, ... .DBX13.0-5 DB3200.DBX1001.0-5
Geometry axis 1: Invert handwheel direction of rotation DB21, ... .DBX15.0 DB3200.DBX1003.0
Geometry axis 2: Invert handwheel direction of rotation DB21, ... .DBX19.0 DB3200.DBX1007.0
Geometry axis 3: Invert handwheel direction of rotation DB21,... .DBX23.0 DB3200.DBX1011.0
Activate contour handwheel DB21, ... .DBX30.0-2 DB3200.DBX14.0-2
Contour handwheel simulation on DB21, ... .DBX30.3 DB3200.DBX14.3
Contour handwheel simulation negative direction DB21, ... .DBX30.4 DB3200.DBX14.4
Invert contour handwheel direction of rotation DB21, ... .DBX31.5 DB3200.DBX15.5
Orientation axis 1: Activate handwheel DB21, ... .DBX320.0-2 -
Orientation axis 1: Traversing key lock DB21, ... .DBX320.4 -
Orientation axis 1: Rapid traverse override DB21, ... .DBX320.5 -
Orientation axis 1: Traversing keys minus/plus DB21, ... .DBX320.6-7 -
Orientation axis 1:
Machine function 1 INC ... Var. INC DB21, ... .DBX321.0-5 -
Orientation axis 1: Invert handwheel direction of rotation DB21, ... .DBX323.0 -
Extended Functions
3.12 Data lists

Orientation axis 2:
Orientation axis 3:
3.12.3.5 Signals from channel

DRF selected DB21, ... .DBX24.3 DB1700.DBX0.3
Handwheel override active (path axes) DB21, ... .DBX33.3 DB3300.DBX1.3
Contour handwheel active DB21, ... .DBX37.0-2 DB3300.DBX5.0-2
Invert contour handwheel direction of rotation active DB21, ... .DBX39.5 DB3300.DBX7.5
Geometry axis 1 Handwheel active DB21, ... .DBX40.0-2 DB3300.DBX1000.0-1
Traversing requests minus/plus DB21, ... .DBX40.4-5 DB3300.DBX1000.4-5
Traversing command minus/plus DB21, ... .DBX40.6-7 DB3300.DBX1000.6-7
Active machine function 1 INC ...
Var. INC DB21, ... .DBX41.0-5 DB3300.DBX1001.0-5
Handwheel direction of rotation
inversion active DB21, ... .DBX43.0 DB3300.DBX1003.0
Extended Functions
3.12 Data lists

Orientation axis 1 Handwheel active DB21, ... .DBX332.0-2 -
Traversing request minus/plus DB21, ... .DBX332.4-5 -
Traversing command minus/plus DB21, ... .DBX332.6-7 -
inversion active DB21, ... .DBX335.0 -
JOG retract active DB21, ... .DBX377.4 DB3300, DBX4005.4
Retraction data available DB21, ... .DBX377.5 DB3300, DBX4005.5
3.12.3.6 Signals to axis/spindle

Feedrate override DB31, ... .DBB0 DB380x.DBB0
Override active DB31, ... .DBX1.7 DB380x.DBX1.7
Delete distance-to-go/spindle reset DB31, ... .DBX2.2 DB380x.DBX2.2
Activate handwheel DB31, ... .DBX4.0-2 DB380x.DBX4.0-2
Traversing key lock DB31, ... .DBX4.4 DB380x.DBX4.4
Rapid traverse override DB31, ... .DBX4.5 DB380x.DBX4.5
Traversing keys minus/plus DB31, ... .DBX4.6-7 DB380x.DBX4.6-7
Machine function 1 INC ... Var. INC DB31, ... .DBX5.0-5 DB380x.DBX5.0-5
Invert handwheel direction of rotation DB31, ... .DBX7.0 DB380x.DBX7.0
JOG fixed point approach DB31, ... .DBX13.0-2 DB380x.DBX1001.0-2

Position reached with coarse/fine exact stop DB31, ... .DBX60.6-7 DB390x.DBX0.6-7
Handwheel override active DB31, ... .DBX62.1 DB390x.DBX2.1
Handwheel active DB31, ... .DBX64.0-2 DB390x.DBX4.0-2
Traversing request minus/plus DB31, ... .DBX64.4-5 DB390x.DBX4.4-5
Extended Functions
3.12 Data lists

Traversing command minus/plus DB31, ... .DBX64.6-7 DB390x.DBX4.6-7
Active machine function 1 INC ... Var. INC DB31, ... .DBX65.0-5 DB390x.DBX5-0-5
Position restored, measuring system 1/2 DB31, ... .DBX71.4-5 DB390x.DBX11.4-5
JOG approach fixed point active DB31, ... .DBX75.0-2 DB390x.DBX1001.0-2
JOG approach fixed point reached DB31, ... .DBX75.3-5 DB390x.DBX1001.3-5
Handwheel direction of rotation inversion active DB31, ... .DBX67.0 DB390x.DBX7.0
3.12.4 System variable
Identifier Description
$AA_POSRES Axis state "Position restored"
3.12.5 OPI variable
3.12.5.1 OPI variable
retractState, bit 0 Retraction data available
retractState, bit 1 JOG retract active
retractState, bits 2 - 3 Retraction axis
aaPosRes Axis state "Position restored".
Extended Functions
K3: Compensations 4
4.1 Introduction
Accuracy errors
The accuracy of machine tools is impaired as a result of deviations from the ideal geometry,
power transmission faults and measuring system errors. Temperature differences and
mechanical forces often result in great reductions in precision when large workpieces are
machined.
Compensation functions
Some of these deviations can usually be measured during commissioning and then
compensated for during operation on the basis of values read by the positional actual-value
encoder and other sensory devices. State-of-the-art CNC controls have compensation
functions that are active on an axis for axis basis.
The following compensation functions are available:
Temperature compensation
Backlash compensation
Mechanical backlash compensation
Dynamic backlash compensation
Interpolatory compensation
Compensation of leadscrew errors and measuring system errors
Compensation of sag and angularity errors
Dynamic feedforward control (following error compensation)
Friction compensation (quadrant error compensation)
Conventional friction compensation
Electronic counterweight
Parameterization
These compensation functions can be set for each machine individually with axis-specific
machine data.
Activation
The compensations are active in all operating modes of the control as soon as the input data
are available. Any compensations that require the position actual value are not activated until
the axis reaches the reference point.
Extended Functions
K3: Compensations
4.2 Temperature compensation
Position display
The normal actual-value and setpoint position displays ignore the compensation values and
show the position values of an ideal machine. The compensation values are output in the
"Diagnosis" operating area of the "Axis/Spindle Service" window.
4.2.1 Description of functions
Deformation due to temperature effects

Heat generated by the drive equipment or high ambient temperatures (e.g. caused by
sunlight, drafts) cause the machine base and parts of the machinery to expand. This
expansion depends, among other things, on the temperature and on the thermal conductivity
of the machine parts.
Effects
Due to the thermal expansion of the machinery, the actual positions of the axes change
depending on temperature. This has a negative impact on the precision of the workpieces
being machined.
By activating the "temperature compensation" function, actual value changes due to
temperature effects can be compensated on an axis-by-axis basis.
Sensor equipment
To provide effective temperature compensation, a number of temperature sensors for
acquiring a temperature profile are needed in addition to the actual position data from
existing encoders.
Since temperature-dependent changes occur relatively slowly, the PLC can acquire and
preprocess the temperature profile in a minutes cycle, for example.
Error curves
In order to implement temperature compensation, the actual-value offsets over the
positioning range of the axis must be measured at a given temperature (T) and plotted. This
produces an error curve for this temperature value. Error curves must be produced for
different temperatures.
Extended Functions
K3: Compensations
Error curve characteristic

If an axis position reference point P0 is selected, an offset in the reference point
(corresponds to the "position-independent component" of the temperature compensation)
can be observed as the temperature changes, and because of the change in length an
additional offset in the other position points, which increases with the distance to the
reference point (corresponds to the "position-dependent component" of the temperature
compensation).
The error curve for a given temperature T can generally be represented with sufficient
accuracy by a straight line with a temperature dependent gradient and reference position.
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Compensation equation
The compensation value Kx is calculated on the basis of current actual position Px of this
axis and temperature T according to the following equation:
Kx = K0 (T) + tan (T) * (Px - P0)
The meaning is as follows:
Kx: Temperature compensation value of axis at position Px

K0: Position-independent temperature compensation value of axis
Px: Actual position of axis
P0 Reference position of axis
tan Coefficient for the position-dependent temperature compensation (corresponds
to the gradient of the approximated error line)
Extended Functions
K3: Compensations
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Figure 4-1 Approximated error line for temperature compensation
Activation
The following conditions must be fulfilled so that the temperature compensation can be
activated:
1. The compensation type is selected (MD32750, see "Commissioning (Page 227)").
2. The parameters for the compensation type are defined (see "Commissioning
(Page 227)").
3. The axis is referenced:
DB31, ... DBX60.4 or 60.5 =1 (referenced/synchronized 1 or 2 respectivelly)
As soon as these conditions are fulfilled, the temperature compensation value for the
position actual value is added to the setpoint in all modes and the machine axis traverses
through this distance. If the compensation value Kx is positive, the axis moves in the
negative direction.
If the reference position is then lost, e.g. because the encoder frequency has been exceeded
(DB31, ... DBX60.4 or 60.5 = 0), compensation processing is deactivated.
Clock cycle
The compensation values are determined in the interpolation cycle.
Display
The total compensation value calculated from the temperature and sag compensation
functions belonging to the actual position is output in the "Diagnosis" operating area of the
"Axis/Spindle Service" window.
Extended Functions
K3: Compensations
Parameter adaptation for temperature changes

Since the approximated error line applies only to the instantaneous temperature value, the
parameters of the error lines that are newly generated when the temperature rises or falls
must be sent to the NCK again. Only in this way can expansion due to heat always be
correctly compensated.
When temperature T changes, the parameters which are temperature-dependent, i.e. (K0,
tan and P0) also change and can thus always be overwritten by the PLC or by means of a
synchronized action.
It is thus possible for the machine-tool manufacturer to emulate the mathematical and
technological relationship between the axis positions and temperature values via the PLC
user program and thus calculate the various parameters for the temperature compensation.
The temperature parameters are transferred to the NCK using the variable services (FB2
(GET) "Read data" and FB3 (PUT) "Write data").
For more information on handling and supplying FB2 and FB3 see:
Reference:
Function Manual Basic Functions; Basic PLC Program (P3)
Smooth the compensation value

To prevent overloading of the machine or tripping of monitoring functions in response to step
changes in the temperature compensation parameters, the compensation values are
distributed over several IPO cycles by an internal control function as soon as they exceed
the maximum compensation value specified for each IPO cycle (MD32760, see
"Commissioning (Page 227)").
4.2.2 Commissioning
Temperature-dependent parameters
Error curves for different temperatures can be defined for each axis. For each error curve the
following parameters must be determined and then entered in the setting data:
Position-independent temperature compensation value K0:
SD43900 $SA_TEMP_COMP_ABS_VALUE
Reference position P0 for position-dependent temperature compensation:
SD43920 $SA_TEMP_COMP_REF_POSITION
Gradient tan for position-dependent temperature compensation:
SD43910 $SA_TEMP_COMP_SLOPE
Extended Functions
K3: Compensations
Temperature compensation type and activation

The temperature compensation type is selected and the temperature compensation
activated using the axis-specific machine data:
MD32750 $MA_TEMP_COMP_TYPE (temperature compensation type)
Bit Value Meaning Associated parameters

0 Position independent temperature compensation SD43900
0 Not active
1 Active
1 Position-dependent temperature compensation SD43920, SD43910
0 Not active
1 Active
2 Temperature compensation in tool direction MD20390
0 Not active $MC_TOOL_TEMP_COMP_ON
(Activate temperature
1 Active compensation tool length)
Maximum compensation value per IPO clock cycle

The maximum possible compensation value per IPO cycle, i.e. the maximum distance that
can be traversed in an IPO cycle as a result of the temperature compensation, is limited
using machine data:
MD32760 $MA_COMP_ADD_VELO_FACTOR (velocity increase as a result of
compensation)
The specified value acts as a factor and is referred to the maximum axis velocity (MD32000
$MA_MAX_AX_VELO).
MD32760 also limits the maximum gradient of the error line (tan ) of the temperature
compensation.
Extended Functions
K3: Compensations
4.2.3 Example
4.2.3.1 Commissioning the temperature compensation for the Z axis of a lathe

Commissioning of temperature compensation is described below using the example of a Z
axis on a lathe.
Determining the error characteristic of the Z axis

In order to determine the temperature-dependent error characteristic of the Z axis, proceed
as follows:
Uniform temperature increase by traversing the axis across the whole Z axis traversing
range (in the example: from 500 mm to 1500 mm)
Measuring the axis position in increments of 100 mm
Measuring the actual temperature at the leadscrew
Executing a traversing measuring cycle every 20 minutes
The mathematical and technological relationships and the resulting parameters for
temperature compensation are derived from the recorded data. The calculated deviation
errors for a specific temperature, which refer to the actual position of the Z axis displayed by
the NC, are represented in graphic form in the diagram below.
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Figure 4-2 Error curves determined for the Z axis
Extended Functions
K3: Compensations
Specifying parameters
The temperature compensation parameters must now be determined on the basis of the
measurement results (see diagram above).
Reference position P0
As the diagram above illustrates, there are basically two methods of parameterizing
reference position P0:
1. P0 = 0 with position-independent temperature compensation value K0 0
2. P0 0 with position-independent temperature compensation value K0 = 0
In this case, version 2 is chosen, which means that the position-independent temperature
compensation value is always 0. The temperature compensation value therefore only
consists of the position-dependent component.
The following parameters are obtained:
MD32750 $MA_TEMP_COMP_TYPE = 2
(only position-dependent temperature compensation active)
P0 = 320 mm SD43920 $SA_TEMP_COMP_REF_POSITION = 320
(reference position for position-dependent temperature compensation)
Coefficient tan (T)
In order to determine the dependency of coefficient tan of the position-dependent
temperature compensation on the temperature, the error curve gradient is plotted against the
measured temperature:
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Figure 4-3 Characteristic of coefficient tan as a function of measured temperature T
With the appropriate linearization, coefficient tan depends on T as follows:

tan(T) = (T - T0) * TKmax * 10-6/ (Tmax - T0)
with
T0 = temperature at which position-dependent error = 0; [degrees]
Extended Functions
K3: Compensations
4.3 Backlash compensation
Tmax = maximum measured temperature; [degrees]

TKmax = temperature coefficient at Tmax; [m/1000 mm]
Therefore, based on the values from the above diagram:
T0 = 23
Tmax = 42
TKmax = 270 m/1000 mm
and tan (T) is therefore:
tan(T) = (T - 23) [degrees] * 270 [m/1000 mm] * 10-6 / (42 - 23) [degrees]
= (T - 23) [degrees] * 14.21 [m/1000 mm] * 10-6
Example:
At a temperature of T = 32.3 degrees, therefore: tan = 0.000132
PLC user program

The formula given above must be used in the PLC user program to calculate the coefficient
tan (T) which corresponds to the measured temperature; this must then be written to the
following NCK setting data:
SD43910 $SA_TEMP_COMP_SLOPE (gradient for position-dependent temperature
compensation)
According to the example above:
SD43910 $SA_TEMP_COMP_SLOPE = 0.000132
4.3.1 Mechanical backlash compensation
4.3.1.1 Description of functions
Mechanical backlash
When force is transmitted between a moving machine part and its drive (e.g. ball screw),
there is normally a small amount of backlash because adjusting mechanical parts so that
they are completely free of backlash would result in too much wear and tear on the machine.
Thus, backlash (play) can occur between the machine component and the measuring
system.
Extended Functions
K3: Compensations
Effects
In the case of axes/spindles with indirect measuring systems, mechanical backlash falsifies
the traversing path. For example, when the direction of movement is reversed, an axis will
travel too much or too little by the amount of the backlash.
Positive backlash (normal case) Negative backlash
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The encoder leads the machine part (e.g. The encoder lags behind the machine part
table). Since the actual position acquired by (e.g. table). The table travels too far as the
the encoder also leads the real actual position actual position of the table leads the actual
of the table, the table travels too short a position detected by the encoder.
distance.
Compensation
To compensate for the mechanical backlash, the axis-specific actual value is corrected by
the axis-specific backlash amount specified when commissioning (MD32450, see
"Commissioning (Page 233)") every time the axis/spindle changes direction.
Activation
The mechanical backlash compensation is always active in all operating modes after
reference point approach.
Display
The compensation value that belongs to the current actual position is displayed in the
"Diagnostics" operator area of the "Axis/Spindle Service" window as the total compensation
calculated from LEC, mechanical and dynamic backlash compensation.
Extended Functions
K3: Compensations
4.3.1.2 Commissioning
Backlash
The mechanical backlash is measured at high velocity with a measuring system attached to
the machine table.
The determined offset value is entered in the axis-specific machine data:
MD32450 $MA_BACKLASH (backlash)
For positive backlash (normal case), the compensation value should be entered as a positive
value and for a negative backlash, as negative value.
After activation of the machine data (NewConfig), the measurement is repeated and the
effect of the mechanical backlash compensation checked.
Note
The circularity test integrated in the HMI can be used to visualize the error.
2nd measuring system

If there is a 2nd measuring system for the axis/spindle, a backlash compensation must be
entered for this too. As the second measuring system is mounted in a different way from the
first measuring system, the backlash can be different from that of the first measuring system.
When the measuring system is switched over the associated compensation value is always
automatically activated.
Weighting factor for backlash

The backlash can be weighted by a factor dependent on the particular parameter set:
MD32452 $MA_BACKLASH_FACTOR (backlash weighting factor)
Value range: 0.01 ... 100.0
Preset: 1.0
Application: e.g. compensation of gear-stage-dependent backlash.
Maximum tolerance for position actual value switchover

The user has the option of applying the backlash compensation value gradually in several
increments when the relevant axis reverses direction. This prevents a setpoint step change
on the axes from causing corresponding errors.
The contents of the following axis-specific machine data determine the increment with which
the backlash compensation value (MD32450) is applied.
MD36500 $MA_ENC_CHANGE_TOL (Max. tolerance on position actual value switchover)
Please note that the backlash compensation is only fully calculated after <n> servo cycles
(<n> = MD32450 / MD36500). An excessive time span can cause the triggering of a
standstill monitoring alarm. If MD36500 > MD32450, then the compensation is performed in
one servo cycle.
Extended Functions
K3: Compensations
4.3.2 Dynamic backlash compensation
Dynamic backlash
A dynamic backlash can occur for machine types with sliding guides. Depending on the axial
dynamic response (velocity, jerk, etc.) used to approach an end position, the machine slide
reaches the programmed end position or stops earlier because of the static friction. The
resulting position error is direction-symmetric.
Compensation
To compensate for the dynamic backlash, half the signed compensation value
(MD32456Commissioning (Page 235), see "") is applied in accordance with the relevant
traversing direction of the axis. Compensation value is applied as ramp.
Activation
The dynamic backlash compensation is activated by the PLC only in required the situations:
DB31, ... DBX25.0 (activate dynamic backlash compensation)
Note
The machine tool manufacturer specifies in the PLC user program the "required" situations
for the activation of the dynamic backlash compensation. Such situations result with traversal
of the axes with G1, in the JOG mode or with the handwheel.
The NC uses the following interface to return the required activation to the PLC:
DB31, ... DBX102.0 (active dynamic backlash compensation)
Requirement
The axes to be compensated must be homed.
Display
The compensation value that belongs to the current actual position is displayed in the
"Diagnostics" operator area of the "Axis/Spindle Service" window as the total compensation
calculated from LEC, mechanical and dynamic backlash compensation.
Extended Functions
K3: Compensations
4.4 Interpolatory compensation
Compensation value for the dynamic backlash compensation

Once the mechanical backlash at highspeed has been determined by measurement and
compensated using MD32450 $MA_BACKLASH (see "Commissioning (Page 233)" of the
mechanical backlash compensation), the same measurement action is repeated for slower
velocities. The backlash now measured represents the compensation value for the dynamic
backlash compensation. The value is entered in the machine data:
MD32456 $MA_BACKLASH_DYN (compensation value for dynamic backlash
compensation)
Limitation of the compensation value change

Compensation value for the dynamic backlash compensation is applied as ramp. The ramp
is specified by the following machine data:
MD32457 $MA_BACKLASH_DYN_MAX_VELO (limitation of the dynamic backlash
compensation value change)
The value is specified as percentage of the configured maximum axis velocity
(MD32000 $MA_MAX_AX_VELO). The standard setting is 1%.
4.4.1 General properties
Function
The "Interpolatory compensation" function allows position-related dimensional deviations (for
example, leadscrew and measuring system errors, sag and angularity errors) to be
corrected.
The compensation values are measured during commissioning and stored in a table as a
position-related value. During operation, the corresponding axis is compensated between
interpolation points during linear interpolation.
Methods
Within "interpolatory compensation", a distinction is made between the two following
compensation methods:
Compensation of leadscrew errors and measuring system errors
Compensation of sag and angularity errors
Many of the characteristics of these two compensation methods are identical and are
therefore subsequently described for the two methods.
Extended Functions
K3: Compensations
Terms
Important terms for "interpolatory compensation" are:
Compensation value
The difference between the axis position measured by the position actual-value encoder
and the required programmed axis position (= axis position of the ideal machine). The
compensation value is often also referred to as the correction value.
Basic axis
Axis whose setpoint position or actual position forms the basis for calculating a
compensation value.
Compensation axis
Axis whose setpoint position or actual position is modified by a compensation value.
Interpolation point
A position of the basic axis and the corresponding compensation value of the
compensation axis.
Compensation table
Table of interpolation points and compensation values (see below)
Compensation relation
Assignment of the basic axis and the corresponding compensation axis and the reference
to the corresponding compensation table.
Compensation tables
Because the mentioned dimensional deviations directly affect the accuracy of workpiece
machining, they must be compensated for by the relevant position-dependent compensation
values. The compensation values are derived from measured error curves and entered in the
control in the form of compensation tables during commissioning. A separate table must be
created for each compensation relation.
Entering compensation tables

The size of the compensation table, i.e. the number of interpolation points, must first be
defined in a machine data. After the next POWER ON, the compensation tables are
generated by the NC and preassigned a value of "0".
The compensation values and additional table parameters are entered in the compensation
tables using special system variables. Data can be loaded in two different ways:
By starting an NC program with the parameter values.
By transferring the compensation tables from an external computer to the control.
Extended Functions
K3: Compensations
Note
Compensation tables can only be loaded if the corresponding compensation function is
not active:
MD32700 $MA_ENC_COMP_ENABLE (interpolatory compensation) = 0
MD32710 $MA_CEC_ENABLE (enable sag compensation) = 0
These compensation values are not lost when the control is switched off because they are
stored in the static user memory. They can be updated if necessary (e.g. following re-
measuring because of machine aging).
Note
When changing machine data:
MD18342 $MN_MM_CEC_MAX_POINTS
MD38000 $MA_MM_ENC_COMP_MAX_POINTS
is formatted during the next system run-up of the static user memory (see Section "S7:
Memory configuration (Page 755)").
Linear interpolation between interpolation points

The traversing path to be compensated delineated by the start and end positions is divided
up into several (number depends on error curve shape) path segments of equal size (see
diagram below). The actual positions that limit these sub-paths are referred to as
"interpolation points" below. A compensation value must be entered for each interpolation
point (actual position) during commissioning. The compensation value applied between two
interpolation points is generated on the basis of linear interpolation using the compensation
values for the adjacent interpolation points (i.e. adjacent interpolation points are linked along
a line).
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Figure 4-4 Linear interpolation between the interpolation points
Extended Functions
K3: Compensations
Compensation value at reference point

The compensation table should be structured such that the compensation value at the
reference point is "zero".
4.4.2 Compensation of leadscrew errors and measuring system errors
4.4.2.1 Measuring system error compensation (MSEC)
Leadscrew and measuring system errors

The measuring principle of "indirect measurement" on NC-controlled machines is based on
the assumption that the lead of the ball screw is constant at any point within the traversing
range, so that the actual position of the axis can be derived from the position of the drive
spindle (ideal case). However, manufacturing tolerances result in dimensional deviations of
varying degrees of severity on spindles (so-called leadscrew errors).
Added to this are the dimensional deviations (differences in reference division) caused by
the measuring system as well as its mounting on the machine (so-called measuring system
errors), plus any machine-dependent error sources.
Compensation
With "measuring system error compensation" (referred to below as MSEC), the base and
compensation axes are always identical. It is therefore an axial compensation for which a
definition of the base axis and compensation axis in the compensation table is not
necessary.
Note
The leadscrew error compensation (LEC) is part of the measuring system error
compensation.
The principle of the MSEC is to modify the axis-specific position actual value by the assigned
compensation value in the interpolation cycle and to apply this value to the machine axis for
immediate traversal. A positive compensation value causes the corresponding machine axis
to move in the negative direction.
The magnitude of the compensation value is not limited and is not monitored. In order to
avoid impermissibly high velocities and accelerations caused by compensation, small
compensation values must be selected. Large compensation values can cause other axis
monitoring functions to output alarms (e.g. contour monitoring, speed setpoint limitation).
If the axis to be compensated has a 2nd position measuring system, a separate
compensation table must be created and activated for each measuring system. The correct
table is automatically used when switching between measuring systems.
Extended Functions
K3: Compensations
Preconditions / activation
The MSEC is only active until the following pre-conditions:
The compensation values are stored in the static user memory and are active (after
POWER ON).
The function has been activated for the relevant machine axis:
MD32700 $MA_ENC_COMP_ENABLE [<e>] = 1
with: <e> = Position measuring system

<e> = 0 Measuring system 1
The axis has been referenced:
DB31, ... DBX60.4 or 60.5 =1 (referenced/synchronized 1 or 2)
As soon as these conditions have been fulfilled, the axis-specific actual value is modified by
the compensation value in all modes and traversed by the machine axis immediately.
If the reference is then lost, e.g. because the encoder frequency has been exceeded (DB31,
... DBX60.4 or 60.5 = 0), compensation processing is deactivated.
Number of compensation interpolation points (MD38000)

For every machine axis and for every measuring system (if a 2nd measuring system is
installed), the number of reserved interpolation points of the compensation table must be
defined and the necessary memory reserved with the following machine data:
MD38000 $MA_MM_ENC_COMP_MAX_POINTS[<e>,<AXi>]

<AXi> = Axis name (e.g. X1, Y1, Z1)

The required number of compensation interpolation points is calculated as follows:
$$B(1&B&203B0$;>H$;L@$$B(1&B&203B0,1>H$;L@
00B(1&B&203B0$;B32,176>H$;L@ $$B(1&B&203B67(3>H$;L@
Extended Functions
K3: Compensations
Measuring system-specific parameters of the compensation table

The position-related compensations as well as additional table parameters should be saved
in the form of system variables for each machine axis as well as for each measuring system
(if a 2nd measuring system is being used):
$AA_ENC_COMP[<e>,<N>,<AXi>]
(Compensation value for interpolation point N in the compensation table)
<N> = interpolation point (axis position)
For every individual interpolation point the compensation value must be entered in the
table.
<N> is limited by the maximum number of interpolation points of the particular
compensation table (MD38000 $MA_MM_ENC_COMP_MAX_POINTS):
0 N MD38000 -1
The size of the compensation value is not limited.
Note
The first and last compensation values remain active over the entire traversing range;
i.e. these values should be set to "0" if the compensation table does not cover the entire
traversing range.
$AA_ENC_COMP_STEP[<e>,<AXi>] (distance between interpolation points)

The distance between interpolation points defines the distance between the
compensation values in the relevant compensation table.
$AA_ENC_COMP_MIN[<e>,<AXi>] (initial position)
The initial position is the axis position at which the compensation table for the relevant
axis begins ( interpolation point 0).
The compensation value for the initial position is $AA_ENC_COMP[<e>,0,<AXi>)].
The compensation value of interpolation point 0 is used for all positions smaller than the
initial position (does not apply for tables with modulo function).
$AA_ENC_COMP_MAX[<e>,<AXi>] (end position)
The end position is the axis position at which the compensation table for the relevant axis
ends ( interpolation point <k>).
The compensation value for the end position is $AA_ENC_COMP[<e>,<k>,<AXi>)].
The compensation value of interpolation point <k> is used for all positions larger than the
end position (exception for table with modulo function).
The following supplementary conditions apply to interpolation point <k>:
for k = MD38000 - 1:
The compensation table is fully utilized!
for k < MD38000 - 1:
The compensation table is not fully utilized. Compensation values entered in the table
that are greater than k are ignored.
for k > MD38000 - 1:
The compensation table is limited by a control function which reduces the end
position. Compensation values that are greater than k are ignored.
Extended Functions
K3: Compensations
$AA_ENC_COMP_IS_MODULO[<e>,<AXi>] (compensation with modulo function)

System variable to activate/deactivate the compensation with modulo function:
$AA_ENC_COMP_IS_MODULO[<e>,<AXi>] = 0: Compensation without modulo
function
$AA_ENC_COMP_IS_MODULO[<e>,<AXi>] = 1: Compensation with modulo function
When compensation with modulo function is activated, the compensation table is
repeated cyclically, i.e. the compensation value at position $AA_ENC_COMP_MAX (
interpolation point $AA_ENC_COMP[<e>,<k>,<AXi>]) is immediately followed by the
compensation value at position $AA_ENC_COMP_MIN ( interpolation point
$AA_ENC_COMP[<e>,<0>,<AXi>]).
For rotary axes with modulo 360 degrees it is therefore suitable to program 0
($AA_ENC_COMP_MIN) as the initial position and 360 ($AA_ENC_COMP_MAX) as the
end position.
The compensation values entered for these two positions should be the same as
otherwise the compensation value jumps from MAX to MIN at the transition point and vice
versa.
CAUTION
When the compensation values are entered, it is important that all interpolation points
within the defined range are assigned a compensation value (i.e. there should be no
gaps). Otherwise, the compensation value that was left over from previous entries at
these positions is used for these interpolation points.
Note
Table parameters containing position information are automatically converted when the
system of units is changed (change from MD10240
$MN_SCALING_SYSTEM_IS_METRIC).
The position information is always interpreted in the actual system of units. Conversion
must be implemented externally.
Automatic conversion of the position data can be configured as follows:
External conversion is no longer necessary.
Reference:
Function Manual Basic Functions; Velocities, Setpoint/Actual Value Systems, Closed-
Loop Control (G2)
Extended Functions
K3: Compensations
4.4.2.3 Example
The following example shows compensation value inputs for machine axis X1.
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$AA_ENC_COMP[0,0,X1]=0.003 ; 1st compensation value (interpolation point
0): +3m
$AA_ENC_COMP[0,1,X1]=0.01 ; 2nd compensation value (interpolation point
1): +10m
$AA_ENC_COMP[0,2,X1]=0.012 ; 3rd compensation value (interpolation point
2): +12m
...
$AA_ENC_COMP[0,800,X1]=-0.0 ; Last compensation value (interpolation point
800): 0m
$AA_ENC_COMP_STEP[0,X1]=1.0 ; Distance between interpolation points 1.0 mm
$AA_ENC_COMP_MIN[0,X1]=-200.0 ; Compensation starts at -200.0 mm
$AA_ENC_COMP_MAX[0,X1]=600.0 ; Compensation ends at +600.0 mm
$AA_ENC_COMP_IS_MODULO[0,X1]=0 ; Compensation without modulo function
M17
For this example, the configured number of interpolation points must be 801:
MD38000 $MA_MM_ENC_COMP_MAX_POINTS 801
The memory required in the static user memory is 6.4 KB (8 bytes per compensation value).
Extended Functions
K3: Compensations
4.4.3 Compensation of sag and angularity errors
Sag errors
Weight can result in position-dependent displacement and inclination of moved parts since it
can cause machine parts and their guides to sag.
Also large workpieces (e.g. cylinders) sag under their own weight.
Angularity errors
If moving axes are not positioned in exactly the required angle (e.g. perpendicular) with
respect to one another, increasingly serious positioning errors will occur as the deviation
from zero point becomes greater.
Compensation
In contrast to the MSEC, the base and compensation axes need not be identical for "Sag
compensation" or "Angularity error compensation", requiring an axis assignment in every
compensation table.
In order to compensate for sag of one axis (base axis) which results from its own weight, the
absolute position of another axis (compensation axis) must be influenced. "Sag
compensation" is therefore an inter-axis compensation.
As illustrated in the diagram below, the further the machining head moves in the negative Y1
axis direction, the more the cross-arm sags in the negative Z1 axis direction.
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Figure 4-5 Example of sag caused by own weight
Extended Functions
K3: Compensations
The error must be recorded in the form of a compensation table that contains a
compensation value for the Z1 axis for every actual value position in the Y1 axis. It is
sufficient to enter the compensation values for the interpolation points.
When the Y1 axis traverses, the control calculates the corresponding compensation value in
the Z1 axis in interpolation cycles performing linear interpolation for positions between the
interpolation points. This compensation is sent to the position control loop as an additional
setpoint. A positive compensation value causes the corresponding machine axis to move in
the negative direction.
Depending on the requirement, several compensation relations can be defined for one axis.
The total compensation value results from the sum of all the compensation values of this
axis.
Setting options
The many ways in which the compensation value for sag compensation can be
produced/influenced are listed below (see diagram below).
1. An axis can be defined as the input variable (base axis) for several compensation tables
(settable via system variables).
2. An axis can be defined as the recipient of the output variable (compensation axis) of
several compensation tables (settable via system variable). The total compensation value
is derived from the sum of the individual compensation values.
The following definitions apply for the maximum number of possible compensation tables:
Maximum number of tables available for all axes:
2 * maximum number of axes of system
Maximum number of tables configured for one particular compensation axis:
1 * maximum number of axes of system
3. An axis can be both a base axis and a compensation axis at any one time. The
programmed (required) position setpoint is always used to calculate the compensation
values.
4. The scope of action of the compensation (starting and end position of the base axis) and
the distance between the interpolation points can be defined for every compensation
table (settable via system variables).
5. Compensation can be direction-dependent (settable via system variables).
6. Every compensation table has a modulo function for cyclic evaluation (settable via
system variables).
7. A weighting factor by which the table value is multiplied (definable as a setting data which
can therefore be altered by the part program, PLC or the user at any time) can be
introduced for every compensation table.
Extended Functions
K3: Compensations
8. Every compensation table can be multiplied with any other compensation table in pairs
(i.e. also with itself) using the "table multiplication" function. A system variable is used to
link the multiplication. The product is added to the total compensation value of the
compensation axis.
9. The following options are available to activate the compensation:
Machine data:
MD32710 $MA_CEC_ENABLE[<AXi>] (enable sag compensation)
enables the sum of all compensation relationships for machine axis <AXi>.
With the setting data:
SD41300 $SN_CEC_TABLE_ENABLE[<t>] (pre-assignment for the compensation
table)
evaluation of the compensation table [<t>] is enabled.
It is thus possible e.g. to alter the compensation relationships either from the part
program or from the PLC user program (e.g. switching over the tables), depending on
the machining requirements.
Extended Functions
246
Figure 4-6
K3: Compensations
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Extended Functions
K3: Compensations
Complex compensation
Since it is possible to use the position of an axis as the input quantity (base axis) for several
tables, to derive the total compensation value of an axis from several compensation
relationships (tables) and to multiply tables, it is also possible to implement sophisticated and
complex beam sag and angularity error compensation systems.
This function also makes it possible to deal with different error sources efficiently. For
example, it is possible to combine a table with a modulo function for a periodic recurring
error component with a second table without a modulo function for an aperiodic error
component for the same axis.
Leadscrew errors can also be compensated with this function by parameterizing an identical
axis for the base and compensation axes. However, in contrast to the MSEC, measuring-
system switchovers are not automatically registered in this case.
The "sag compensation" function does not become active until the following conditions are
fulfilled:
The function has been activated for the relevant machine axis (compensation axis):
MD32710 $MA_CEC_ENABLE[<AXi>] = 1
The compensation values are stored in the static user memory and are active (after
POWER ON).
Evaluation of the relevant compensation table has been enabled:
SD41300 $SN_CEC_TABLE _ENABLE[<t>] = 1
The current measuring system of the base and compensation axes has been referenced:
DB31, ... DBX60.4 or 60.5 =1 (referenced/synchronized 1 or 2)
As soon as these conditions have been fulfilled the setpoint position of the compensation
axis is altered in all modes with reference to the setpoint position of the base axis and the
corresponding compensation value and is then immediately traversed by the machine axis.
If the reference is then lost, e.g. because the encoder frequency has been exceeded (DB31,
... DBX60.4 or 60.5 = 0), compensation processing is deactivated.
Number of compensation interpolation points

The number of required interpolation points in the compensation table must be defined for
every compensation relationship and the memory space required is reserved using the
MD18342 $MN_MM_CEC_MAX_POINTS[<index>] (maximum number of interpolation points
for sag compensation), with index = 0, 1, 2, ... (2 * maximum number of axes) - 1
The required number of interpolation points of a compensation table is calculated as follows:
$1B&(&B0$;>W@$1B&(&B0,1>W@
00B&(&B0$;B32,176>W@
$1B&(&B67(3>W@
Extended Functions
K3: Compensations
Table parameters
The position-related compensation values as well as additional table parameters should be
saved for every compensation relationship in the form of system variables:
$AN_CEC[<index>,<N>] (compensation value for interpolation point <N> of
compensation table [<t>])
<N> = interpolation point (position of the basic axis), with 0 N (value of MD18342) - 1
The particular compensation value of the compensation axis must be entered in the table
for each individual interpolation point.
$AN_CEC_INPUT_AXIS[<index>] (basic axis)
Name of machine axis whose setpoint is to be used as the input for the compensation
table [<t>].
$AN_CEC_OUTPUT_AXIS[<index>] (compensation axis)
Name of machine axis to which the output of the compensation table [<t>] is applied.
Note
In multi-channel systems the "general axis names" AX1 ... must be defined, if the names
of machine axis and channel axis are identical.
$AN_CEC_STEP[<index>] (interpolation point distance)

The interpolation point distance defines the distance between the input values for the
compensation table [<t>].
$AN_CEC_MIN[<index>] (initial position)
The initial position is the basic axis position at which the compensation table [<t>] begins
( interpolation point 0).
The compensation value for the initial position is $AN_CEC [<t>,0].
The compensation value of interpolation point 0 is used for all positions smaller than the
initial position (exception: table with modulo functions).
$AN_CEC_MAX[<index>] (end position)
The end position is the basic axis position at which the compensation table ends, =
interpolation point <k>.
The compensation value for the end position is $AN_CEC [<index>,<k>].
The compensation value of interpolation point <k> is used for all positions larger than the
end position (exception: table with modulo functions).
The following boundary conditions apply to interpolation point k:
For k = MD18342 - 1:
The compensation table is fully utilized!
For k < MD18342 - 1:
The compensation table is not fully utilized. The compensation values entered that are
greater than k are ignored.
For k > MD18342 1:
The compensation table is limited by a control function which reduces the end
position. Compensation values that are greater than k are ignored.
Extended Functions
K3: Compensations
$AN_CEC_DIRECTION[<index>] (direction-dependent compensation)

This system variable is used to set whether the compensation table [<t>] should apply to
both traversing directions of the basic axis or only either the positive or negative direction:
$AN_CEC_DIRECTION[<index>] = 0:
Table applies to both directions of travel of the basic axis
$AN_CEC_DIRECTION[<index>] = 1:
Table applies only to the positive traversing direction of the basic axis
$AN_CEC_DIRECTION[<index>] = -1:
Table applies only to the negative traversing direction of the basic axis
Possible applications:
Position-dependent backlash compensation can be implemented using two tables, one of
which affects the positive traversing direction, the other of which affects the negative
traversing direction of the same axis.
$AN_CEC_MULT_BY_TABLE [<index>] (table multiplication)
With the table multiplication function, the compensation values of any table can be
multiplied by those of any other table (or even by the same table). The product is added
as an additional compensation value to the total compensation value of the compensation
table.
Syntax:
$AN_CEC_MULT_BY_TABLE[<index>] = <number>
with:
<index> = table index of table 1 of the compensation axis
<number> = table number of table 2 of the compensation axis, with
table number = table index + 1
$AN_CEC_IS_MODULO[<index>] (compensation with modulo function)
System variable to activate/deactivate the compensation with modulo function:
$AA_CEC_COMP_IS_MODULO[<index>] = 0: Compensation without modulo function
$AA_CEC_COMP_IS_MODULO[<index>] = 1: Compensation with modulo function
When compensation with modulo function is activated, the compensation table is
repeated cyclically, i.e. the compensation value at position $AN_CEC_MAX[<index>]
corresponding to interpolation point $AN_CEC[<index>,<k>] is immediately followed by
the compensation value at position $AN_CEC_MIN[<index>] corresponding to
interpolation point $AN_CEC[<index>,0].
These two compensation values should be the same as otherwise the compensation
value jumps from MAX to MIN at the transition point and vice versa.
If modulo compensation is to be implemented with a modulo rotary axis as basic axis, the
compensation table used has to be modulo calculated as well.
Extended Functions
K3: Compensations
Example:
MD30300 $MA_IS_ROT_AX[AX1]=1 ; rotary axis
MD30310 $MA_ROT_IS_MODULO[AX1]=1 ; modulo 360
$AN_CEC_INPUT_AXIS[0] = AX1
$AN_CEC_MIN[0] = 0.0
$AN_CEC_MAX[0] = 360.0
$AN_CEC_IS_MODULO[0] = 1
System of units
Table parameters containing position information are automatically converted when the
system of units is changed (change from MD10240 $MN_SCALING_SYSTEM_IS_METRIC).
The position information is always interpreted in the current measuring system. Conversion
must be implemented externally.
Automatic conversion of the position data can be configured as follows:
With this setting, the following axial machine data is activated:
MD32711 $MA_CEC_SCALING_SYSTEM_METRIC (measuring system for sag
compensation)
The measuring system for all tables effective for this axis is set in this machine data. Hereby,
all position entries are interpreted together with the calculated total compensation value in
the configured measuring system. External conversions of position information are no longer
necessary with a measuring system change.
Monitoring
To avoid excessive velocities and acceleration rates on the machine axis as a result of
applying sag compensation, the total compensation value is monitored and limited to a
maximum value.
The maximum possible total compensation value for sag compensation is defined on an
axis-for-axis basis using the machine data:
MD32720 $MA_CEC_MAX_SUM (maximum compensation value for sag compensation)
If the determined total compensation value is greater than the maximum value, then a
corresponding alarm is output. Program processing is not interrupted. The compensation
value output as an additional setpoint is limited to the maximum value.
Further, changing the total compensation value is also axially limited:
MD32730 $MA_CEC_MAX_VELO (velocity change for sag compensation)
The specified value acts as a factor and is referred to the maximum axis velocity (MD32000
$MA_MAX_AX_VELO).
An appropriate alarm is signaled when the limit value is exceeded. Program processing is
not interrupted. The path not covered because of the limitation is made up as soon as the
compensation value is no longer subject to limitation.
Extended Functions
K3: Compensations
4.4.3.3 Examples
Compensation table for sag compensation of the Y1 axis

The following example shows the compensation table for sag compensation of the Y1 axis.
Depending on the position of the Y1 axis, a compensation value is applied to the Z1 axis.
The 1st compensation table with index = 0 is used for this.

%_N_NC_CEC_INI ;
CHANDATA(1) ;
$AN_CEC[0,0]=0 ;1st compensation value (interpolation point 0)
; for Z1: 0m
$AN_CEC[0,1]=0.01 ;2nd compensation value (interpolation point 1)
; for Z1: +10m
$AN_CEC[0,2]=0.012 ;3rd compensation value (interpolation point 2)
; for Z1: +12m
... ;
$AN_CEC[0,100]=0 ; Last compensation value (interpolation point 101)
; for Z1: 0m
$AN_CEC_INPUT_AXIS[0]=(AX2) ; basic axis Y1
$AN_CEC_OUTPUT_AXIS[0]=(AX3) ; compensation axis Z1
$AN_CEC_STEP[0]=8 ; distance between interpolation points 8.0 mm
$AN_CEC_MIN[0]=-400.0 ; Compensation starts at Y1=-400 mm
$AN_CEC_MAX[0]=400.0 ; Compensation ends at Y1=+400 mm
$AN_CEC_DIRECTION[0]=0 ; Table applies for both directions of travel of Y1.
$AN_CEC_MULT_BY_TABLE[0]=0 ;
$AN_CEC_IS_MODULO[0]=0 ;compensation without modulo function
M17 ;
For this example, the configured number of interpolation points must be 101:
MD18342 $MN_MM_CEC_MAX_POINTS[0] 101
The memory required in the static user memory is at least 808 bytes (8 bytes per
compensation value).
Extended Functions
K3: Compensations
Application for table multiplication

The following example for the compensation of machine foundation sagging illustrates an
application of table multiplication.
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Figure 4-7 Compensation of sag in a foundation
On large machines, sagging of the foundation can cause inclination of the whole machine.
For the boring mill shown above as an example, the compensation of the X1 axis depends
on the position of the X1 axis itself, since this determines the angle of inclination , and on
the height Z1 of the drill.
The compensation values of the X1 and Z1 axes should be linked as follows for a
compensation:
X1 = Z1 * sin(X1) Z1 * (X1)
7DEOH
;VHWS VLQ;

= ;VHWS6&RPS
=VHWS
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Figure 4-8 Table multiplication
Compensation table 1 (index = 0) describes the reaction of axis X1 on axis X1 (sine of the
position-dependent tilting angle (X1)).
Compensation table 2 (index = 1) describes the reaction of axis Z1 on axis X1 (linear).
In table 1, the multiplication of table 1 (index = 0) with table 2 is to be selected:
$AN_CEC_MULT_BY_TABLE[0] = 2
Extended Functions
K3: Compensations
Input of compensation values in a grid structure

The compensation values of the Z axis sag on flat bed machines are often measured in
practice at various points as a function of the X and Y coordinates. Under these
preconditions, it is useful to enter the measured compensation values according to a grid-
type distribution. The interpolation points with the relevant compensation values are
positioned at the intersections of the grid (X-Y plane). Compensation values between these
interpolation points are interpolated linearly by the control.
The following example explains in more detail how sag and angularity compensation can be
implemented by a grid of 4 x 5 (lines x columns) in size. The size of the whole grid is
2000 x 900 mm2. The compensation values are each measured in steps of 500 mm along
the X axis and 300 mm along the Y axis.
Note
The following interdependencies apply for the maximum dimension of the grid (number of
lines and columns):
The number of lines depends on the number of axes in the system (dependent on the
NCU type).
The number of columns is dependent on the maximum number of values which can be
entered in a compensation table (up to a total of 2000 values).
The number of lines and columns is set via the following machine data:
MD18342 $_MN_MM_CEC_MAX_POINTS (maximum number of interpolation points for sag
compensation)
CAUTION
Memory-configuring machine data
Settings made to the MD18342 machine data cause the non-volatile NC user memory to be
automatically re-allocated on system power-on. All the user data in the NC user memory
(e.g. drive and HMI machine data, tool offsets, part programs, etc.) is deleted.
Save the user data before setting the machine data.
Extended Functions
K3: Compensations
<

;
Figure 4-9 Compensation values of z axis with chessboard-like distribution of x-y plane
The application example can be realized with the following part program code:
$MA_CEC_ENABLE[Z1]= FALSE ; Deactivate compensation

; by setting to FALSE.
; The table values can then be
; altered without generation of
; alarm 17070.
NEWCONF ; Activate $MA_CEC_ENABLE
;Define values f_i(x) in the f tables:
;Function values f_1(x) for table with index [0]
$AN_CEC[0,0]=0.1
$AN_CEC[0,1]=0.2
$AN_CEC[0,2]=0.3
$AN_CEC[0,3]=0.4
$AN_CEC[0,4]=0.5

$AN_CEC[1,0]=0.6
$AN_CEC[1,1]=0.7
$AN_CEC[1,2]=0.8
$AN_CEC[1,3]=0.9
$AN_CEC[1,4]=1.0
Extended Functions
K3: Compensations

$AN_CEC[2,0]=1.1
$AN_CEC[2,1]=1.2
$AN_CEC[2,2]=1.3
$AN_CEC[2,3]=1.4
$AN_CEC[2,4]=1.5

$AN_CEC[3,0]=1.6
$AN_CEC[3,1]=1.7
$AN_CEC[3,2]=1.8
$AN_CEC[3,3]=1.9
$AN_CEC[3,4]=2.0
;Enable evaluation of f tables with compensation values

$SN_CEC_TABLE_ENABLE[0]=TRUE
;Define weighting factor of f tables

$SN_CEC_TABLE_WEIGHT[0]=1.0
;Changes to the following table parameters do not take effect until

;a Power On
;Define basic axis X1
$AN_CEC_INPUT_AXIS[0]=(X1)
;Define compensation axis Z1

$AN_CEC_OUTPUT_AXIS[0]=(Z1)
;Define distance between interpolation points for compensation values in f tables

$AN_CEC_STEP[0]=500.0
Extended Functions
K3: Compensations
;Compensation starts at X1=0

$AN_CEC_MIN[0]=0.0
$AN_CEC_MIN[1]=0.0
$AN_CEC_MIN[2]=0.0
$AN_CEC_MIN[3]=0.0
;Compensation ends at X1=2000

$AN_CEC_MAX[0]=2000.0
$AN_CEC_MAX[1]=2000.0
$AN_CEC_MAX[2]=2000.0
$AN_CEC_MAX[3]=2000.0
;Values of f tables with index [t1] are multiplied by values in g tables
;by the number [t2]
;in accordance with the rule of calculation specified above
;Define the g table values for g_i(y) :

;Function values g_1(x) for table with index [4]
$AN_CEC[4,0]=1.0
$AN_CEC[4,1]=0.0
$AN_CEC[4,2]=0.0
$AN_CEC[4,3]=0.0

$AN_CEC[5,0]=0.0
$AN_CEC[5,1]=1.0
$AN_CEC[5,2]=0.0
$AN_CEC[5,3]=0.0

$AN_CEC[6,0]=0.0
$AN_CEC[6,1]=0.0
$AN_CEC[6,2]=1.0
$AN_CEC[6,3]=0.0

$AN_CEC[7,0]=0.0
$AN_CEC[7,1]=0.0
$AN_CEC[7,2]=0.0
$AN_CEC[7,3]=1.0
Extended Functions
K3: Compensations
;Enable evaluation of g tables with compensation values

;Define weighting factor for g tables

;Changes to the following table parameters do not take effect until

;a Power On
;Define basic axis Y1
$AN_CEC_INPUT_AXIS[4]=(Y1)
;Define compensation axis Z1

;Define distance between interpolation points for compensation values in g tables
;Compensation starts at Y1=0

$AN_CEC_MIN[4]=0.0
$AN_CEC_MIN[5]=0.0
$AN_CEC_MIN[6]=0.0
$AN_CEC_MIN[7]=0.0
;Compensation ends at Y1=900

$AN_CEC_MAX[4]=900.0
$MA_CEC_ENABLE[Z1]=TRUE ;Activate compensation again
NEWCONF
Extended Functions
K3: Compensations
;Carry out a program test to check whether the

;compensation is effective
G01 F1000 X0 X0 Z0 G90
R1=0 R2=0
LOOP_Y:
LOOP_X:
STOPRE
X=R1 Y=R2
M0 ; Wait to check the CEC value
R1=R1+500
IF R1 <=2000 GOTOB LOOP_X
R1=0
R2=R2+300
IF R2<=900 GOTOB LOOP_Y
Note
You can read the compensation value under variable "Sag + temperature compensation" on
the user interface. To do so, select softkey "Diagnosis" followed by softkey "Service axis".
The currently effective compensation value is displayed next to the "Sag + temperature
compensation" variable.
;to prepare the table configuration, the Power On

;machine data is set
;cec.md:
;Set option data for commissioning
;Define the number of interpolation points in the compensation tables
;Machine data configures the memory
$MN_MM_CEC_MAX_POINTS[0]=5
$MA_CEC_MAX_SUM[AX3]=10.0 ; Define the maximum
; total compensation value
$MA_CEC_MAX_VELO[AX3]=100.0 ; Limit the maximum changes in the
; total compensation value
M17
Extended Functions
K3: Compensations
Explanation
The compensation values cannot be entered directly as a 2-dimensional grid. Compensation
tables in which the compensation values are entered must be created first.
A compensation table contains the compensation values of one line (four lines in the
example, i.e. four compensation tables). The compensation values 0.1 to 0.5 are entered in
the first table in the example, the compensation values 0.6 to 1.0 in the second table, and so
on. The compensation tables are referred to below as f tables and their values as f_i(x)
(i=number of table).
The compensation values of f tables are evaluated by multiplying them by other tables. The
latter are referred to below as g tables and their values as g_i(y). The number of f tables and
g tables is equal (four in the example).
In g tables, one compensation value in each table is set to 1 and all the others to 0. The
position of compensation value 1 within the table is determined by the table number. In the
first g table, compensation value 1 is positioned at the first interpolation point and, in the
second g table, at the second interpolation point, etc. By multiplying g tables by f tables, the
correct compensation value in each f table is selected by multiplying it by 1. All irrelevant
compensation values are concealed through multiplication by 0.
Using this scheme, compensation value Dz at position (x/y) is calculated according to the
following equation:
Dz(x/y)=f_1(x)*g_1(y) + f_2(x)*g_2(y) + ...
When the compensation value for the actual position of the machine spindle is calculated,
the f table values are multiplied by the g table values according to this rule.
Applied to the example, this means, for instance that compensation value Dz(500/300) is
calculated by multiplying each of the function values f_i(500) in the f tables by the function
values g_i(300) in the g tables:
Dz(500/300) = f_1(1000)*g_1(300) + f_2(1000)*g_2(300) + f_3(1000)*g_3(300) +
f_4(1000)*g_4(300)
Dz(500/300) = 0.2*0 + 0.7*1 + 1.2*0 + 1.7*0 = 0.7
4.4.4 Direction-dependent leadscrew error compensation

If the direction-dependent differences at the compensation points are excessively high, for
an inconsistent backlash or for extremely high demands placed on the precision, then it may
be necessary to apply direction-dependent compensation of the leadscrew error or
measuring system error (for direct position sensing).
Extended Functions
K3: Compensations
Direction-dependent leadscrew error compensation

For the "direction-dependent leadscrew error compensation" ("direction-dependent LEC" or
also "Bidirectional LEC") , two compensation tables are used for each axis. One
compensation table for the positive and one compensation table for the negative traversing
direction. The deviation at the particular compensation point is entered as difference
between the ideal setpoint and measured actual value in the compensation tables. The
control automatically calculates compensation values of intermediate values using linear
interpolation.
The "direction-dependent LEC" is implemented in the SINUMERIK control as a special case
of "sag compensation". This is the reason that the preconditions and conditions of "sag
compensation" apply (see "Compensation of sag and angularity errors (Page 243)").
The activation of the compensation can be checked using a reference measurement, e.g.
using the laser interferometer or in the simplest case, using the service display of the
particular axis.
Note
If the "direction-dependent LEC" is used in parallel to the sag compensation and
compensation of the angularity, then the secondary conditions of these functions must be
taken into consideration together, e.g. the assignment of tables <t> to the particular function.
Measuring the error or compensation values

When commissioning the "direction-dependent LEC" - just the same as when commissioning
the "direction-dependent LEC" - direction-dependent error curves for each axis are
determined using a suitable measuring device (e.g. laser interferometer) (see Section
"Compensation of leadscrew errors and measuring system errors (Page 238)"). A part
program with measurement points and wait times should be generated in order to perform
the measurement (see Section "Example (Page 264)"): Program
"BI_SSFK_MESS_AX1_X.MPF").
Because the various measuring devices offer different support options for the practical
implementation in conjunction with a SINUMERIK control, this process is only generally
described in the following referred to a control.
Note
The measurement for determining the leadscrew error should only be carried out during the
first commissioning if, in the machine data, the traversing directions of the axes in relation to
the machine coordinate system have been correctly set.
Extended Functions
K3: Compensations
Carrying out commissioning

1. Specify the number of compensation interpolation points (also see Section
"Compensation for droop and angularity error: Commissioning (Page 247)")
Each axis should be assigned to one compensation table each for the positive and
negative traversing directions. The number of compensation interpolation points is
defined using the following machine data:
MD18342 $MN_MM_CEC_MAX_POINTS[<t>] (maximum number of interpolation points
for sag compensation)
with: <t> = Index of compensation table
Permissible range: 0 t < 2 * maximum number of axes
CAUTION
User data loss
ALARM 4400 is output when changing MD18342:
"Reorganization of the buffered memory!"
In order that an automatic memory configuration is possible but keeping all of the data
that has been entered up until now, no system boot (POWER ON) must be executed
without first performing a series machine startup.
Example:
MD18342 [0] = 11; 11 interpolation points for the 1st table, e.g. positive traversing
direction, X axis
MD18342 [1] = 11; 11 interpolation points for the 2nd table, e.g. negative traversing
direction, X axis
MD18342 [2] = 21; 21 interpolation points for the 3rd table, e.g. positive traversing
direction, Y axis
MD18342 [3] = 21; 21 interpolation points for the 4th table, e.g. positive traversing
direction, Y axis

MD18342 [61] = ...; number of interpolation points for the 62nd table
2. Perform the series machine startup:
Generate an NC archive with the entries in MD18342 [<t>].
Read-in the generated NC archive.
Note: The NC memory is configured as a result.
The compensation tables are now available.
3. Generate the tables with compensation values for the particular axes and traversing
directions as part program (see Section "Example (Page 264)": Program
"BI_SSFK_MESS_AX1_X.MPF").
Extended Functions
K3: Compensations
4. Execute the part program with compensation values in the control.

AUTOMATIC mode > select program > NC start
Note
Each time before reading-in the compensation tables, the following parameters should
always be set to 0 and then to activate, always be set to 1:
MD32710 $MA_CEC_ENABLE[<AXi>] (enable sag compensation) = 0 1
SD41300 $SN_CEC_TABLE _ENABLE[<t>] (enable the compensation table) = 0 1
The backlash should always be set to 0:
MD32450 $MA_BACKLASH [<e>] (backlash) = 0
The use of the program template "BI_SSFK_TAB_AX1_X.MPF" (see Section "Example
(Page 264)") automates these tasks. When manually entering machine data, the
generally applicable "Activate MD" or "Reset" should be observed.
5. POWER ON (warm restart).

6. Now, comparative measurements can be made using the laser interferometer.
7. To further improve the compensation results, it is also conceivable to correct individual
compensation values in the program. A POWER ON is no longer necessary when
reading-in the table again.
Note
Sequence for SINUMERIK 828D
For SINUMERIK 828D, steps 2 and 3 are eliminated. This is because when the "sag
compensation, multi-dimensional" option is enabled, 8 tables each with 200 interpolation
points per table for the compensation immediately become available. This cannot be
extended!
Note
As described in step 5, the compensation table is downloaded into the program memory as
an executable program and is then transferred into the previously configured memory area of
the control using an NC start. This procedure can be repeated for each table to ensure
transparency. However, it is also possible to download all tables in an initialization step. The
compensation values become active after MD32710[<AXi>] = 1 and a mandatory power
POWER ON.
Note
NC_CEC.INI
The "NC_CEC.INI" file copied via "Commissioning" > "System data" (from the folder "NC
active data" > "sag angularity comp") includes all negotiated sag/angularity and direction-
dependent LEC tables.
Extended Functions
K3: Compensations
Table parameters
The position-related compensations for the particular direction as well as additional table
parameters in the form of system variables should be saved in the compensation table:
$AN_CEC[<t>,<N>] (compensation value for interpolation point <N> of compensation
table [<t>])
$AN_CEC_INPUT_AXIS[<t>] (basic axis)
$AN_CEC_OUTPUT_AXIS[<t>] (compensation axis)
Note
For the "direction-dependent LEC", the basis and compensation axis are identical.
$AN_CEC_STEP[<t>] (interpolation point distance)

$AN_CEC_MIN[<t>] (initial position)
$AN_CEC_MAX[<t>] (end position)
$AN_CEC_DIRECTION[<t>] (direction-dependent compensation)
This system variable is used to set whether the compensation table [<t>] should apply to
both positive and negative traversing directions of the basic axis:
$AN_CEC_DIRECTION[<t>] = 1:
Table applies only to the positive traversing direction of the basic axis
$AN_CEC_DIRECTION[<t>] = -1:
Table applies only to the negative traversing direction of the basic axis
Note
The setting $AN_CEC_DIRECTION[<t>] = 0 (table is effective for both traversing
directions of the basic axis) is not relevant for the "direction-dependent LEC".
$AN_CEC_IS_MODULO[<t>] (compensation with modulo function)
Note
For a detailed description of these system variables (see Section "Compensation for droop
and angularity error: Commissioning (Page 247)").
System of units
See Section "Compensation for droop and angularity error: Commissioning (Page 247)".
Monitoring
See Section "Compensation for droop and angularity error: Commissioning (Page 247)".
Extended Functions
K3: Compensations
4.4.4.3 Example
The direction-dependent compensation tables of the X axis are shown in detail for a three-
axis machine in the fallowing example:
Configuring
Number of compensation interpolation points:
MD18342 $MN_MM_CEC_MAX_POINTS[0] = 11 (Table 1: Axis X, positive traversing
direction)
MD18342 $MN_MM_CEC_MAX_POINTS[1] = 11 (Table 2: Axis X, negative traversing
direction)
Note
It is not necessary to define the number of interpolation points for SINUMERIK 828D,
because when enabling the "sag compensation, multi-dimensional" option, immediately eight
tables each with 200 interpolation points per table for the compensation are available. This
cannot be extended!
Interpolation points
Table <t> [0,<N>]

Number of MD18342 $MN_MM_CEC_MAX_POINTS[0] = 11
interpolation points
Interpolation point 0 1 2 3 4 5 6 7 8 9 10
<N>
Position X -585 -527 -469 -411 -353 -295 -237 -179 -121 -63 -5
Extended Functions
K3: Compensations
Measurement
Setpoint Deviation Checking measurement

position
Position Comp. No. Measurement Direction + Direction - Direction + Direction -
position [mm] [mm] [mm] [mm]
[mm]
$AC_CEC_MIN[<t>] -585 0 -585 0.0000 0.0020 0.0000 -0.0008
1 -527 0.0010 0.0017 -0.0005 -0.0001
2 -469 0.0040 0.0053 -0.0001 -0.0009
3 -411 0.0034 0.0061 0.0001 -0.0009
4 -353 0.0013 0.0030 -0.0005 -0.0006
5 -295 0.0004 0.0016 -0.0002 -0.0003
6 -237 0.0016 0.0027 -0.0004 -0.0007
7 -179 0.0026 0.0043 -0.0004 -0.0004
8 -121 -0.0010 0.0026 0.0000 -0.0011
9 -63 -0.0023 0.0000 -0.0011 -0.0003
$AC_CEC_MAX[<t>] -5 10 -5 -0.0031 -0.0012 -0.0001 -0.0012
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Extended Functions
K3: Compensations
Programming
The following program "BI_SSFK_TAB_AX1_X.MPF" includes the value assignments for the
parameters of the two compensation tables (positive and negative traversing direction) of the
X axis:
;direction-dependent LEC
;1st axis MX1
;Table 1 - positive traversing direction
;Table 2 - negative traversing direction
;--------------------------------------------------------------------------------------
CHANDATA(1)
$MA_CEC_ENABLE[AX1]=0 ;compensation OFF
$SN_CEC_TABLE_ENABLE[0]=0 ;lock Table 1
$SN_CEC_TABLE_ENABLE[1]=0 ;lock Table 2
NEWCONF
;--------------------------------------------------------------------------------------
$AN_CEC[0,0]=0 ;1st compensation value (interpolation point 0)
$AN_CEC[0,1]=0.001 ;2nd compensation value (interpolation point 1)
$AN_CEC[0,2]=0.004 ;3rd compensation value (interpolation point 2)
$AN_CEC[0,3]=0.0034 ;4th compensation value (interpolation point 3)
$AN_CEC[0,8]=-0.001 ;9th compensation value (interpolation point 8)
$AN_CEC[0,9]=-0.0023 ;10th compensation value (interpolation point 9)
$AN_CEC[0,10]=-0.0031 ;last compensation value (interpolation point 10)
$AN_CEC_INPUT_AXIS[0]=(AX1) ;basic axis
$AN_CEC_OUTPUT_AXIS[0]=(AX1) ;compensation axis
$AN_CEC_STEP[0]=58.0 ;interpolation point distance
$AN_CEC_MIN[0]=-585.0 ;compensation starts
$AN_CEC_MAX[0]=-5.0 ;compensation ends
$AN_CEC_DIRECTION[0]=1 ;Table applies for positive traversing directions
$AN_CEC_MULT_BY_TABLE[0]=0 ;no multiplication (not relevant here)
$AN_CEC_IS_MODULO[0]=0 ;compensation without modulo function
;--------------------------------------------------------------------------------------
$AN_CEC[1,0]=0.002 ;(interpolation point 0)
Extended Functions
K3: Compensations

$AN_CEC[1,10]=-0.0012 ;(interpolation point 10)
$AN_CEC_INPUT_AXIS[1]=(AX1) ;basic axis
$AN_CEC_OUTPUT_AXIS[1]=(AX1) ;compensation axis
$AN_CEC_STEP[1]=58. ;interpolation point distance
$AN_CEC_MIN[1]=-585.0 ;compensation starts
$AN_CEC_MAX[1]=-5.0 ;compensation ends
$AN_CEC_DIRECTION[1]=-1 ;Table applies for negative traversing directions
$AN_CEC_MULT_BY_TABLE[1]=0 ;no multiplication (not relevant here)
$AN_CEC_IS_MODULO[1]=0 ;compensation without modulo function (only for rotary axes)
;--------------------------------------------------------------------------------------
$MA_CEC_ENABLE[AX1]=1 ;compensation ON
$SN_CEC_TABLE_ENABLE[0]=1 ;enable Table 1
$SN_CEC_TABLE_ENABLE[1]=1 ;enable Table 2
NEWCONF
M17
Additional tables can be set-up, e.g. for axes Y and Z:

MD18342 $MN_MM_CEC_MAX_POINTS[2] = 90 (Table 3: Axis Y, positive traversing
direction)
MD18342 $MN_MM_CEC_MAX_POINTS[3] = 90 (Table 4: Axis Y, negative traversing
direction)
MD18342 $MN_MM_CEC_MAX_POINTS[4] = 50 (Table 5: Axis Z, positive traversing
direction)
MD18342 $MN_MM_CEC_MAX_POINTS[5] = 50 (Table 6: Axis Z, negative traversing
direction)
4.4.5 Extension of the sag compensation with NCU link - only 840D sl
Application
If a system is operated with NCU link, any number of axes of the NCU link grouping can be
compensated mutually. The two axes that are coupled via sag compensation must be
interpolated on one NCU.
See also:
NCU link (Page 79)
Axis container (Page 100)
Extended Functions
K3: Compensations
Function
The parameterization of the sag compensation function is done by setting system variables
of the form: $AN_CEC ...
These system variables are normally set via a part program that processes the NCK in a
certain channel. The channel axis name can be used in the variables
$AN_CEC_OUTPUT_AXIS or $AN_CEC_INPUT_AXIS. This way, each axis of the channel
can be addressed, even if it is in a different NCU.
A program in Channel 2 can couple Axis ZZ with Axis XX via the following setting (the setting
is valid for the table with the number 0):
$AN_CEC_INPUT_AXIS[0] = (XX)
$AN_CEC_OUTPUT_AXIS[0] = (ZZ)
This way AX3 on NCU-1 is "coupled" with AX2 on NCU-2 (see configuration 1).
The following variants can be used to parameterize if the axes to be coupled are on two
different channels:
Version 1: "Programming with channel axis name":
Two different part programs TP1 and TP2 are created, they are then processed in
different channels.
Axis "ZZ" is coupled to "XR":
View from the part program TP1 in Channel 1:
$AN_CEC_INPUT_AXIS[0] = (XR)
View from the part program TP2 in Channel 2:

$AN_CEC_OUTPUT_AXIS[0] = (ZZ)
Axis AX2 on NCU2 is coupled with Axis AX1 on NCU1 upon restart after TP1 is executed
in Channel 1 and TP2 is executed in Channel 2.
Version 2: "Programming with machine axis name":
One part program is created that runs in any convenient channel of NCU1 and specifies
the machine axis names together with the NCU numbers.
Axis "ZZ" is coupled to "XR":
$AN_CEC_INPUT_NCU[0]=1
$AN_CEC_INPUT_AXIS[0] = (AX1)
$AN_CEC_OUTPUT_NCU[0]=2
$AN_CEC_OUTPUT_AXIS[0] = (AX2)
The NCK monitors whether the axes on the local NCU have actually been interpolated,
i.e. there is a channel that can program these axes. The local NCU is always the NCU on
which the part program runs.
Extended Functions
K3: Compensations
The following axes are allowed for NCU1 as input or output axes in Configuration
1: NC1_AX1, NC1_AX3, NC1_AX4, NC1_AX5, NC2_AX2, NC2_AX6
The data backup from the NCK always delivers the compensation data from the "machine
axis name" view.
Note
The NCU number is to be programmed before the axis name. A sag compensation
between NC1_AX1 and NC1_AX2 is not possible.
Assignment of the axes

The assignment of the input and output axes is done via the following system variables:
$AN_CEC_INPUT_NCU and $AN_CEC_INPUT_AXIS

$AN_CEC_OUTPUT_NCU and $AN_CEC_OUTPUT_AXIS
The system variables become effective only after a restart.
Data backup is always undertaken with machine axis names.
Note
The sag compensation can couple the axis only on one NCU, which can also be traversed
from this NCU either via the part program or via a synchronized action.
These variables are set optionally if the axes (input and output) are not available on the local
NCU. If one uses a channel axis name while programming $AN_CEC_INPUT_AXIS and
$AN_CEC_OUTPUT_AXIS, then the system variables $AN_CEC_INPUT_NCU and
$AN_CEC_OUTPUT_NCU become irrelevant.
The control checks whether the two axes can be interpolated from this NCU, i.e. a program
can traverse the axes on this NCU. The axes can be assigned to different channels. Two
axes belonging to different NCUs can also be compensated. Otherwise the control rejects it
with Alarm 17040.
Both axes of compensation must be interpolated on one NCU, i.e. there may be one or two
part programs that traverse the input and output axes on an NCU.
Extended Functions
K3: Compensations
Axis container
The axis container is a grouping of similar axes. An axis from the group can be assigned to a
channel axis. The assignment is variable, so that the axis in the channel always gets a new
axis from the group assigned to it in the course of time. Thus, the part program can be
programmed with one axis and it can gradually move different axes.
Example:
Four spindles are arranged on a drum. Each spindle carries a tool of the turning machine
and it rotates the drum by 90 degrees in each cycle. The tools are transported from one
machining station to the next in this way. The channel of the machining station must program
only one spindle, though a new spindle is always changed. This is an axis container rotation.
The sag compensation can be combined with the axis container if it is in the basic position,
i.e. $AN_AXCTAS == 0. Otherwise the programming is rejected with Alarm 17040.
"YY" is to be coupled to "XX" (see Configuration 2):
1. Programming with channel axis names
$AN_CEC_INPUT_AXIS[0] = (XX)
$AN_CEC_OUTPUT_AXIS[0] = (YY)
2. Programming with machine axis names

$AN_CEC_INPUT_NCU[0]=1 ; optional ...
$AN_CEC_INPUT_AXIS[0] = (AX2)
$AN_CEC_OUTPUT_NCU[0]=2
$AN_CEC_OUTPUT_AXIS[0] = (AX2
This couples Axis AX2 of NCU1 with Axis 2 of NCU2.
NOTICE
Axis confusion
YY is coupled to XX with each container rotation, there is a different axis behind YY now:
YY "AX5 of NCU-1" is in configuration 3.
Other real axes are coupled after the rotation in this way: In this example, AX-5 of NCU-1 is
coupled to AX-2 of NCU-1.
As a rule:
The coupling is created between two axes from the LAI layer so that other axes participate in
the coupling after each axis container rotation. A new table must be activated for each
container rotation to undertake a coupling exactly between two real axes.
Extended Functions
K3: Compensations
Configuration example
The following figures (Configuration 1, Configuration 2 and Configuration 3) illustrate the axis
configurations of an NCU link that is assembled from two NCUs.
The two channels CHAN-1 and CHAN-2 of NCU-1 are displayed in Configuration 1. Here,
the channel axis names that are defined via the machine data
$MC_AXCONF_CHANAX_NAME_TAB are entered. The channel configuration of the second
NCU is not displayed.
All the axes interpolated by this NCU are compiled in the "Logical NCK machine axis image"
(LAI layer). The assignment between channel and MCS axis layer is done via
$MC_AXCONF_MACHAX_USED.
The assignment between the "Logical NCK machine axis image" and the real axes is
undertaken via the machine data $MN_AXCONF_LOGICMACHAX_TAB. If ones pursues the
connecting line that starts with channel axis ZZ, one ends at Axis AX-2 on NCU-2, i.e. to
traverse the 2nd axis of NCU 2, the following command must be programmed in the 2nd
channel of NCU 1: "N2040 POS[ZZ]=10 FA[ZZ]=1000"
Configuration 2 and Configuration 3 extend the figure of Configuration 1 by one axis
container (CT1) that is set with machine data $MN_AXCT_AXCONF_ASSIGN_TAB1. The
axis container is an overlapping object, i.e. each axis container exists only once for the
whole NCU cluster.
For NCU 1, the participants in the axis container are channel axes YR and YY; the two
channel axes from NCU2 are not displayed. The container contains the real axes NC1_AX5,
NC1_AX6, NC2_AX1 and NC2_AX2. Container YR connects with NC2_AX1 and YY
connects with NC2_AX2 during the ramp up. In Configuration 3, the container has rotated,
i.e. the connection structure has changed. YR is now connected to NC2_AX2 and YY is
connected to NC1_AX5.
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Extended Functions
K3: Compensations
Machine data of Configuration 1
; ########## NCU1 ##########
$MN_NCU_LINKNO = 1
$MN_MM_NCU_LINK_MASK = 1
$MN_MM_LINK_NUM_OF_MODULES = 2
$MN_MM_SERVO_FIFO_SIZE = 3
$MN_ASSIGN_CHAN_TO_MODE_GROUP[1]=1
$MN_AXCONF_LOGIC_MACHAX_TAB[0] = "NC1_AX1"
CHANDATA(1)
$MC_AXCONF_MACHAX_USED[0]=1
$MC_AXCONF_CHANAX_NAME_TAB[0] = "XR"
$MC_AXCONF_CHANAX_NAME_TAB[1] = "YR"
$MC_AXCONF_CHANAX_NAME_TAB[2] = "ZR"
CHANDATA(2)
$MC_REFP_NC_START_LOCK=0
Extended Functions
K3: Compensations
$MC_AXCONF_CHANAX_NAME_TAB[0] = "XX"
$MC_AXCONF_CHANAX_NAME_TAB[1] = "YY"
$MC_AXCONF_CHANAX_NAME_TAB[2] = "ZZ"
M30
; ########## NCU-2 ##########
$MN_NCU_LINKNO = 2
CHANDATA(1)
M30
Extended Functions
K3: Compensations
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Figure 4-11 Configuration 2: NCU link with axis container in output state
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Figure 4-12 Configuration 3: NCU link with axis container in rotary state
Extended Functions
K3: Compensations
Machine data of Configuration 2
; ########## NCU1 ##########
$MN_NCU_LINKNO = 1
$MN_ASSIGN_CHAN_TO_MODE_GROUP[1]=1
$MN_AXCONF_LOGIC_MACHAX_TAB[4] = "CT1_SL3"
$MN_AXCT_AXCONF_ASSIGN_TAB1[0] = "NC1_AX5"
$SN_AXCT_SWWIDTH[0] = 1
CHANDATA(1)
$MC_AXCONF_CHANAX_NAME_TAB[0] = "XR"
$MC_AXCONF_CHANAX_NAME_TAB[1] = "YR"
$MC_AXCONF_CHANAX_NAME_TAB[2] = "ZR"
Extended Functions
K3: Compensations
CHANDATA(2)
$MC_REFP_NC_START_LOCK=0
$MC_AXCONF_CHANAX_NAME_TAB[0] = "XX"
$MC_AXCONF_CHANAX_NAME_TAB[1] = "YY"
$MC_AXCONF_CHANAX_NAME_TAB[2] = "ZZ"
M30
; ########## NCU-2 ##########
$MN_NCU_LINKNO = 2
CHANDATA(1)
M30
Extended Functions
K3: Compensations
4.4.6 Special features of interpolatory compensation
Measurement
The "Measurement" function supplies the compensated actual positions (ideal machine)
required by the machine operator or programmer.
TEACH IN
The "TEACH IN" function also uses compensated position values to determine the actual
positions to be stored.
Software limit switch

The ideal position values (i.e. the position actual values corrected by the MSEC and
backlash compensation functions) are also monitored by the software limit switches.
Position display
The position actual-value display in the machine coordinate system shows the ideal
(programmed) actual position value of the axis (ideal machine).
The position actual value determined by the measuring system plus the sum of MSEC and
backlash compensation (= position actual value, measuring system 1/2) is displayed the
"axis/spindle" service display (operating area "Diagnosis")
Compensation value display

The following compensation values are also output in the "Axis/spindle" service display
(operating area "Diagnosis"):
Absolute compensation value measuring system 1 or 2
Displayed value corresponds to the total compensation value calculated from MSEC and
backlash compensation associated with the actual position of the axis (measuring system
1 or 2).
Compensation, sag + temperature
Display value is the sum of the compensation values from sag compensation and
temperature compensation for the actual position of the axis.
Reference point loss

If the reference point of the basic axis is lost (DB31, ... DBX60.4 or 60.5 = 0), then MSEC
and sag compensation functions are deactivated in the axes involved. These are
automatically reactivated when the reference point is reached.
Access protection
Currently there is no protection against access to the compensation tables.
Extended Functions
K3: Compensations
4.5 Dynamic feedforward control (following error compensation)
Setting servo enables

As a result of the compensation relationship, a traversing movement by the base axis may
also cause the compensation axis to move, making it necessary for controller enable signals
to be set for these axes (PLC user program). Otherwise the compensation only has a limited
effect.
Traversing signal output

The traversing signals in the compensation axis are output every time the compensation
function is switched on/off and every time the number of active compensation tables
changes.
Any change in the compensation value caused by the base axis motion does not result in
output of traversing signals in the compensation axis.
4.5.1 General properties
Axial following error

The remaining system deviation of the position controller when traversing a machining axis is
known as axial following error. Expressed in another way, the axial following error is the
difference between the setpoint position and the actual position of the machine axis.
Effects
Particularly during acceleration in contour curvatures, e.g. circles and corners, this following
error leads to undesirable, velocity-dependent contour violations.
Compensation
The axial following error can be reduced almost to zero with the help of the "dynamic
feedforward control". The function is therefore also called "following error compensation".
Methods
There are two "dynamic feedforward control" methods:
Speed feedforward control (velocity-dependent)
Torque feedforward control (acceleration-dependent)
Extended Functions
K3: Compensations
Activation
The feedforward control method is selected and activated using the machine data:
MD32620 $MA_FFW_MODE (feedforward control mode)
Value Meaning
0 No feedforward control
1 Speed feedforward control with PT1 balancing
2 Torque feedforward control with PT1 balancing
3 Speed feedforward control with Tt balancing
4 Torque feedforward control with Tt balancing
Activation/deactivation in part program

The following axis-specific machine data can be used to define that the feedforward control
for the respective axis/spindle can be activated and deactivated by the part program:
MD32630 $MA_FFW_ACTIVATION_MODE (activate feedforward control from program)
Value Meaning
0 The feedforward control cannot be activated and deactivated from the part program. This
means that the state specified using MD32620 $MA_FFW_MODE is always effective for the
axis/spindle.
1 The feedforward control can be activated and deactivated from the part program. The
operation becomes active immediately.
2 The feedforward control can be activated and deactivated from the part program. The
operation only becomes active the next time that the axis comes to a standstill.
The feedforward control is activated/deactivated from the part program using the operations:
FFWON: Feedforward control ON
FFWOF: Feedforward control OFF
The default setting (i.e. M30 even after reset) is entered using the channel-specific machine
data:
MD20150 $MC_GCODE_RESET_VALUES (initial setting of the G groups)
FFWON/FFWOF is active for all axes/spindles in the axis mode, where:
MD32630 $MA_FFW_ACTIVATION_MODE = 1 (or 2)
and
MD32620 $MA_FFW_MODE = 1, 2, 3 or 4
The identical MD32630 setting should be used for axes that interpolate with each other.
Extended Functions
K3: Compensations
The feedforward control should only be activated or deactivated while the axis/spindle is
stationary in the axis mode, in order to prevent jerky motion. Hence the switchover is
delayed automatically up to the next standstill through block search stop.
Note
A preprocessing stop has no effect for command or PLC axes traversing asynchronously to
the part program processing. To ensure that FFWON/FFWOF only has an effect on the
axis/spindle when it is next stationary in the axis mode, you must explicitly set MD32630 = 2
for each axis/spindle in the axis mode (see also "Forward feed control for command- and
PLC axes (Page 284)").
4.5.2 Speed feedforward control
Function
In the case of speed feedforward control, a velocity setpoint is also applied directly to the
input of the speed controller. With this value the following error can be reduced to nearly
zero (i.e. system deviation is 0) when the velocity is constant.
Commissioning
The following axis-specific parameters must be defined for the speed feedforward control
during commissioning:
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Equivalent time constant of the speed control loop (MD32810)

The equivalent time constant of the speed control loop must be determined accurately (e.g.
graphically from a speed setpoint step response) and entered into the following machine
data to correctly set the speed feedforward control:
MD32810 $MA_EQUIV_SPEEDCTRL_TIME (equivalent time constant speed control loop for
feedforward control)
Extended Functions
K3: Compensations
Feedforward control factor for speed feedforward control (MD32610)

The additional velocity setpoint can be weighted using a factor:
MD32610 $MA_VELO_FFW_WEIGHT
Range of values: 0 ... 1
"0" means: no feedforward control. As standard, the factor has a value of 1 ( 100%).
The factor should remain set at 100%, as this value is the optimum setting for an optimally
set control loop for the axis/spindle as well as a precisely determined equivalent time
constant of the speed control loop.
Fine adjustment
The speed feedforward control for the particular axis/spindle can be optimized by making
slight changes (fine tuning) to the equivalent time constants of the speed control loop
(MD32810).
To make this check, the axis/spindle should be traversed at a constant velocity and in the
service display "Axis/spindle", the "System deviation" should be checked.
A small acceleration and a high feedrate should be chosen so that the values can be easily
read on the service display. This produces very long acceleration phases from which it is
easy to read off the control deviation.
Example:
MD32300 $MA_MAX_AX_ACCEL = 0.1 ; Maximum axis acceleration = 0.1 m/s2

MD32000 $MA_MAX_AX_VELO = 20000.0 ; Maximum axis velocity
= 20000.0 mm/min
; Part program for setting the equivalent time constant

G1 F20000
FFWON
LOOP:
X1000
X0
GOTOB LOOP
M30
References
For detailed information about setting the equivalent time constants of the speed control loop
(MD32810) refer to:
Function Manual, Basic Functions; Velocities, Setpoint / Actual Value Systems, Closed-
Loop Control (G2), Section: Optimization of the control
Extended Functions
K3: Compensations
4.5.3 Torque feedforward control
Function
In the case of torque feedforward control, an additional current setpoint proportional to the
torque is applied directly to the current controller input. This value is formed using the
acceleration and moment of inertia.
Application
Torque feedforward control is required to achieve high contour accuracy where the demands
on the dynamic response are very high. If set correctly, the following error can almost be
completely compensated even during high acceleration.
Commissioning
The following axis-specific parameters must be defined during commissioning for torque
feedforward control:
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Equivalent time constant of the current control loop (MD32800)

The equivalent time constant of the current control loop must be determined accurately (e.g.
graphically from the step response of the current control loop) and entered in the following
machine data in order to correctly set the torque feedforward control:
MD32800 $MA_EQUIV_CURRCTRL_TIME (equivalent time constant current control loop for
feedforward control)
Total moment of inertia of axis (MD32650)

The total moment of inertia (moment of inertia of drive plus load referred to the motor shaft)
of the axis must be determined and entered in the following machine data:
MD32650 $MA_AX_INERTIA (inertia for torque feedforward control)
Extended Functions
K3: Compensations
Fine adjustment
The torque feedforward control for the particular axis/spindle can be optimized by making
slight changes (fine tuning) to the values in MD32800 and MD32650.
To make a check, the following error should be recorded via the trace functionality. In
addition to traversing at a constant velocity, the following error should be monitored
especially when the axis/spindle accelerates.
Note
As a result of the extremely fast sequences when accelerating, when commissioning the
torque feedforward control, the service display cannot be used to check the fine adjustment.
References
For detailed information about setting the equivalent time constants of the current control
loop (MD32810) refer to:
Function Manual, Basic Functions; Velocities, Setpoint / Actual Value Systems, Closed-
Loop Control (G2), Section: Optimization of the control
4.5.4 Dynamic response adaptation
Function
For axes that interpolate with one another, but with different axial control loop response
times, dynamic response adaptation can be used to achieve identical time responses of all
axes to ensure optimum contour accuracy without loss of control quality.
Commissioning
Time constant for dynamic response adaptation (MD32910)
The difference between the equivalent time constants of the "slowest" speed or current
control loop and the particular axis should be entered as time constant for the dynamic
response adaptation in the following machine data.
MD32910 $MA_DYN_MATCH_TIME (time constant of dynamic response adaptation)
Example:
Equivalent time constants of the speed control loop (MD32810) for active speed feedforward
control of axes 1, 2 and 3:
Axis 1: 2 ms
Axis 2: 4 ms (dynamically the slowest axis)
Axis 3: 1 ms
Extended Functions
K3: Compensations
This means that the following values are obtained for the time constant of the dynamic
response adaptation MD32910:
Axis 1: 2 ms
Axis 2: 0 ms
Axis 3: 3 ms
Activation (MD32900)
The dynamic response adaptation is only active if the following machine data is set:
MD32900 $MA_DYN_MATCH_ENABLE= 1
Reference
Function Manual, Basic Functions; Velocities, Setpoint-Actual Value Systems, Closed-Loop
Control (G2), Chapter: "Optimizing the closed-loop control"
4.5.5 Forward feed control for command- and PLC axes
Function
For command and PLC axes, it must be prevented that the feedforward control is
activated/deactivated at higher velocities as follows:
MD32630 $MA_FFW_ACTIVATION_MODE = 2
With this setting, the FFWON/FFWOF operation only becomes active below the stationary
velocity (MD36060 $MA_STANDSTILL_VELO_TOL) configured for this particular axis.
If the switchover instruction coincides with an axis motion, the required switchover is
executed only in the next stoppage condition of the axis. This avoids the following error
being suddenly established/reduced.
Note
A stoppage velocity set to a very high value can lead to the changeover of the feedforward
control in the movement. Controls can be activated depending on the existing following error.
Extended Functions
K3: Compensations
Commissioning
We recommend the following procedure when checking the feedforward control for
command and PLC axes:
1. Check the stoppage velocity in MD36060.
2. Check the existing following error of the axis in stoppage condition.
3. Setting the changeover condition and activating it:
MD32630 = 2
4. Traverse axis in the part program using the POSA operation.
5. Execute FFWON during the axis motion.
6. The Kv factor and following error displayed in the service display "Axis/spindle" must not
jump.
7. A higher Kv factor and a lower following error are only obtained for traversing motion
following standstill. However, the feedforward control is active only from the stoppage
condition.
Essentially the same as when activating the feedforward control, for deactivation, the
following applies:
1. Traverse axis in the part program using the POSA operation.
2. Execute FFWOF during the axis motion.
3. The Kv factor and following error displayed in the service display "Axis/spindle" must not
jump.
4. A lower Kv factor and a higher following error are only obtained for traversing motion
following standstill. However, the feedforward control is inactive only from the stoppage
condition.
Example
In the following program example, axis A is traversed asynchronously to the path. An attempt
is made to activate the feedforward control in the channel while traversing. Contrary to the
geometry axes X, Y and Z, the feedforward control is not immediately effective for axis A.
Here one waits for the stoppage after N60. Axis A then traverses with the feedforward
control in N70.
Program code
N10 FFWOF
N20 POSA[A]=1000 FA[A]=10000
N30 G4 F1
N40 FFWON
N50 G0 X10 Y10 Z10
N60 WAITP(A)
N70 POSA[A]=1500 FA[A]=10000
N80 WAITP(A)
M30
Extended Functions
K3: Compensations
4.5.6 Secondary conditions
Axes that are interpolating axes with one another

Also for axes that interpolate with one another, the feedforward control parameter should be
optimally set for each axis, i.e. also several axes that are interpolating with one another can
have different feedforward control parameters.
Check contour monitoring

As the two equivalent time constants:
MD32810 $MA_EQUIV_SPEEDCTRL_TIME (equivalent time constant speed control loop
for feedforward control)
and
MD32800 $MA_EQUIV_CURRCTRL_TIME) (equivalent time constant current control
loop for feedforward control)
also influence the contour monitoring, this should be subsequently checked.
Reference:
Function Manual, Basic Functions; Axis Monitoring, Protection Zones (A3)
Effect on servo gain factor

When the feedforward control is set correctly, the response to setpoint changes in the
controlled system under speed feedforward control is as dynamic as that of the speed
control loop or, under torque feedforward control, as that of the current control loop, i.e. the
servo gain factor entered into MD32200 $MA_POS_CTRLGAIN hardly has any effect on the
control behavior (e.g. corner errors, overshoots, circle/radius errors).
On the other hand, feedforward control does not affect the response to disturbances
(synchronism). In this case, the servo gain factor entered in MD32200 is the active factor.
Service display "Servo gain factor"

When a feedforward control is active, the servo gain of the axis (corresponds to servo gain
factor active as response to setpoint changes) shown in the service display "axis/spindle" is
very high.
Extended Functions
K3: Compensations
4.6 Friction compensation (quadrant error compensation)
4.6.1 General function description

In addition to the mass inertia and the machining forces, the frictional forces in the gearing
and guideways of the machine influence the behavior of a machine axis. During the
acceleration of an axis from standstill, especially the transition from static friction to the
significantly smaller sliding friction has a negative affect with regard to the contour accuracy.
The sudden change in the friction force results in a briefly increased following error. With
interpolating axes (path axes), this results in significant contour violations. For circles, the
contour violations occur especially at the quadrant transitions due to the standstill of one of
the involved axis at the direction reversal.
Therefore, an additional setpoint pulse is injected as a compensation value for this friction or
quadrant error compensation when the axis accelerates from standstill, i.e. at the transition
from static to sliding friction. In this way, contour violations can be almost completely avoided
at the quadrant transitions of circular contours.
Acceleration-dependent friction compensation

In most cases, a compensation value independent of the axial acceleration with constant
amplitude is sufficient for the quadrant error compensation. However, if the compensation
value is dependent on the acceleration, an adaptation characteristic can be activated via the
"friction compensation with adaptation" in order to model this behavior.
Circularity test
The easiest way to commission the friction compensation is with the circularity test
integrated in the user interface. A circle is traversed and the circular contour generated on
the machine based on the actual position values of the involved machine axes and the
deviations to the programmed ideal circular contour, especially at the quadrant transitions,
displayed in graphical form.
The circularity test can be found on the user interface under:
SINUMERIK Operate
"Operating area switchover" > "Commissioning" > "Optimization/test" > "Circularity test"
Extended Functions
K3: Compensations
Note
Switch off setpoint-related compensations
The following compensations affect the position setpoint and must be switched off before the
measurement of the axes involved in the circularity test:
Sag and angularity compensation (CEC):
MD32710 $MA_CEC_ENABLE[ <axis> ] = 0
Direction-dependent leadscrew error compensation:
MD32710 $MA_CEC_ENABLE[ <axis> ] = 0
Temperature compensation:
MD32750 $MA_TEMP_COMP_TYPE[ <axis> ] = 0
4.6.3 Friction compensation with a constant compensation value
4.6.3.1 Function activation
Enable
The general enabling of the friction compensation is via:
MD32490 $MA_FRICT_COMP_MODE[ <axis> ] = 1
Activation
The activation of the friction compensation with constant compensation value is via:
MD32500 FRICT_COMP_ENABLE[ <axis> ] = 1 (friction compensation ON)
MD32510 $MA_FRICT_COMP_ADAPT_ENABLE[ <axis> ] = 0 (adaptation OFF)
Parameters
The following parameters are calculated for friction compensation with constant
compensation value:
MD32520 $MA_FRICT_COMP_CONST_MAX (maximum compensation value)
For friction compensation with constant compensation value, the parameterized value is
injected as compensation value.
MD32540 $MA_FRICT_COMP_TIME (friction compensation time constant)
The compensation value is injected via a DT1 filter. The compensation value decays
according to the parameterized time constants.
Extended Functions
K3: Compensations
4.6.3.2 commissioning
Circularity test
It is recommended that the circularity test be used for the commissioning of the friction
compensation with constant injected value, as described above. The commissioning
sequence is divided into the following steps:
1. Perform circularity test without friction compensation
2. Perform circularity test with friction compensation and initial parameter values
3. Perform circularity tests with friction compensation and modified parameter values
4. Complete circularity tests with friction compensation and optimized parameter values
Circularity test without friction compensation

A circularity test without friction compensation should be performed to determine the initial
quality of the circular contour at the quadrant transitions. To do this, switch off the friction
compensation temporarily:
MD32500 FRICT_COMP_ENABLE[ <axis> ] = 0
The following figure shows a typical example of quadrant transitions without friction
compensation:
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Figure 4-13 Quadrant transitions without friction compensation
Then switch on the friction compensation with constant compensation value:

MD32500 FRICT_COMP_ENABLE[ <axis> ] = 1
Extended Functions
K3: Compensations
Circularity test with friction compensation and initial parameter values

It is recommended that a relatively small compensation value, as well as a time constant of
just a few position control cycles, be set as initial parameter values, e.g.:
MD32520 $MA_FRICT_COMP_CONST_MAX[ <axis> ] = 10 [mm/min]
MD32540 $FRICT_COMP_TIME[ <axis> ] = 0.008 [ms]
The circularity test performed with these parameter values provides an initial assessment of
the friction compensation.
Compensation value too small

Too small a compensation value (MD32520) in the circularity test is indicated by insufficient
compensation of the contour deviations at the quadrant transitions.
&RXQWHU
,, ,
&RXQWHU
,,, ,9
Figure 4-14 Compensation value set too small
Extended Functions
K3: Compensations
Compensation value too large

Too large a compensation value (MD32520) in the circularity test is indicated by
overcompensation of the contour deviations at the quadrant transitions.
&RXQWHU
,, ,
&RXQWHU
,,, ,9
Figure 4-15 Compensation value set too large
Time constant too small

Too small a time constant (MD32540) in the circularity test is indicated by short-time
compensation of the contour deviations at the quadrant transitions which immediately
increase thereafter.
&RXQWHU
,, ,
&RXQWHU
,,, ,9
Figure 4-16 Compensation time constant set too small
Extended Functions
K3: Compensations
Time constant too large

Too large a time constant (MD32540) in the circularity test compensates the contour
deviations at the quadrant transitions. (Requirement: The optimum compensation value has
already been determined.) However, with too large a time constant, the compensation value
applies too long and results in an overcompensation at the next circular contour.
&RXQWHU
,, ,
&RXQWHU
,,, ,9
Figure 4-17 Time constant set too large
Extended Functions
K3: Compensations
Optimization of the compensation parameters

To optimize the compensation parameters, the circularity test must be repeated several
times and the values changed in small increments. It is recommended that the optimization
be performed with different values for radius and path velocity that are typical for the
machining operations performed on the machine.
Each effect of a parameter change should be checked with a subsequent circularity test and
documented.
Mean value generation

If different parameter values result for different radii and path velocities, the best values
should be determined via mean value generation.
Good friction compensation setting

With a good friction compensation setting, "no" contour violations can be detected at the
quadrant transitions.
&RXQWHU
,9 ,
&RXQWHU
,,, ,,
Figure 4-18 Good friction compensation setting
Acceleration-dependent compensation value

If the compensation value proves to be acceleration-dependent, the "friction compensation
and adaptation" described below can be injected in a following step.
Extended Functions
K3: Compensations
4.6.4 Friction compensation with acceleration-dependent compensation value

If the compensation value is highly dependent on the acceleration, normally a smaller
compensation value must be injected for optimum compensation with larger accelerations
than for smaller accelerations. This dependency can be modeled via the following adaptation
characteristic.
QPD[
QPLQ
D D D D
% % % %
nmax Maximum compensation value

nmin Minimum compensation value
a1 Acceleration value 1
Bn Acceleration range with n = 1, 2, ... 4
with: Accelerations: a1 < a2 < a3
Compensation values: nmax > nmin, in special cases also nmax < nmin
The compensation value n is calculated according to the respective acceleration range B1

to B4 as follows:
Range With acceleration a Compensation value n

B1 a < a1 n = nmax * a / a1
B2 a1 a a2 n = nmax
B3 a2 < a < a3 n = nmax + [(nmin - nmax) / (a3 - a2)] * (a - a2)
B4 a a3 n = nmin
Extended Functions
K3: Compensations
4.6.4.2 Function activation
Enable
The general enabling of the friction compensation is via:
MD32490 $MA_FRICT_COMP_MODE[ <axis> ] = 1
Activation
The activation of the friction compensation with adaptation characteristic is performed via:
MD32500 FRICT_COMP_ENABLE[ <axis> ] = 1 (friction compensation ON)
MD32510 $MA_FRICT_COMP_ADAPT_ENABLE[ <axis> ] = 1 (adaptation characteristic
OFF)
4.6.4.3 commissioning
To determine the characteristic parameters, the optimum compensation value nopt must be
determined at various operating points of the specified dynamic response range. See
Section "commissioning (Page 289)". A sufficiently large number of measured values for
large path velocities and small circle radii is particularly important.
For the evaluation of the determined value pairs, it is recommended that these are displayed
graphically:
nopt = f(a), with nopt = optimum compensation value and a = acceleration at the quadrant
transitions.
The parameters of the adaptation characteristic determined from the measurement results
must then be entered in the machine data.
Characteristic parameters
Acceleration values
The acceleration which arises at the quadrant transitions of the axis changing direction is
calculated as follows:
a = v2 / r, with v = path velocity and r = circle radius
Note
The path velocity and therefore the axial acceleration a can be varied simply via the feedrate
override switch.
The acceleration values a1, a2 and a3 determined as characteristic parameters must be

entered in the following machine data. The following condition must be satisfied: a1 < a2 < a3
MD32550 $MA_FRICT_COMP_ACCEL1 (acceleration value 1)
Extended Functions
K3: Compensations
Compensation values
The compensation values nmin, nmax determined as characteristic parameters must be
entered in the following machine data:
MD32520 $MA_FRICT_COMP_CONST_MAX (maximum compensation value)
MD32530 $MA_FRICT_COMP_CONST_MIN (minimum compensation value)
Note
If satisfactory results cannot be obtained for very small path velocities, the computational
resolution may have to be increased:
MD10200 $MA_INT_INCR_ PER_MM (computational resolution for linear positions)
MD10210 $MA_INT_INCR_PER_DEG (computational resolution for angular positions)
4.6.5 Compensation value for short traversing blocks

The compensation value determined for the quadrant error compensation can lead to
overcompensation in short traversing blocks. The overcompensation can be avoided by
reducing the compensation value specifically for traversing blocks that are traversed within
one interpolation cycle. However, the size of the reduction is a value that must be
determined empirically as it depends to a large extent for every axis on the particular
situation at the machine. A percentage of the compensation value determined in the
circularity test is set via the machine data:
MD32580 $MA_FRICT_COMP_INC_FACTOR (compensation value for short traversing
blocks)
Extended Functions
K3: Compensations
4.7 Measures for hanging (suspended axes)
4.7.1 Electronic counterweight
Axis without counterweight

For axes that have a weight load without counterweight, then after the brake is released, the
hanging (suspended) axis drops and the following response is obtained:
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Figure 4-19 Drop of a hanging axis without counterweight
Extended Functions
K3: Compensations
"Electronic counterweight" function

A hanging (suspended) axis can almost be completely prevented from dropping (sagging)
using the "electronic counterweight" function.
The electronic counterweight prevents axes with a weight load from sagging when the
closed-loop control is switched on. After releasing the brake, the constant counterweight
torque maintains the position of the vertical axis.
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Figure 4-20 Lowering of a vertical axis with electronic weight compensation
Commissioning
Note
The "electronic counterweight" is commissioned through the drive!
Reference
For additional information, see the following:
SINAMICS S120 Function Manual Drive Functions
Extended Functions
K3: Compensations
4.7.2 Reboot delay
Side-effect of a reboot from the user interface

The activation of the machine data, etc., from the user interface requires that the NCK is
booted. This can cause hanging axes to drop somewhat. The "reboot delay" function can be
used to avoid this.
Reboot delay
The reboot delay results in the NCK and PLC being shut down with a delay and
communicates the pending shutdown in order to prevent hanging (suspended) axes from
dropping.
Note
The reboot delay acts only for the controlled POWER ON from the user interface.
The reboot delay is not activated for a POWER FAIL (power failure) or a hardware reboot.
Reboot sequence
The command software can use the "_N_IBN_SS" PI service to initiate a reboot of the NCK
and the PLC.
NCK immediately activates alarm 2900 in response to the PI service.
Mechanical axis brakes can be activated in the time that the NCK allows to expire from the
PI service to the reboot (reboot delay time, refer to MD10088
$MN_REBOOT_DELAY_TIME).
Reactions to alarm 2900

The following NC/PLC signals are canceled, i.e. set to zero:
DB11 DBX 6.3 (mode group ready) ; all mode groups
DB21, DBX 36.5 (channel ready) ; all channels
DB31, DBX 61.2 (axis ready) ; all axes
The motor brakes along the current limit.
For further details, see machine data:
MD36610 $MA_AX_EMERGENCY_STOP_TIME (braking ramp time when errors
occur)
MD36620 $MA_SERVO_DISABLE_DELAY_TIME (switchoff delay controller release)
Note
After the shutdown delay, the NCK withdraws the controller enable (MD36620) of the
position control.
Extended Functions
K3: Compensations
The following NC/PLC interface signals remain at 1:

DB10 DBX108.7 (NC ready)
By using the machine data:
MD11410 $MN_SUPPRESS_ALARM_MASK (mask for suppressing special alarms) (BIT20)
the alarm 2900 is suppressed, however, the NCK triggers the same reactions.
As alarm 2900 deactivates the axis position control, this alarm must be configured to initiate
that the mechanical brakes are closed by the PLC. Rebooting the PLC forces the PLC
outputs to change to defined zero. The brakes must be connected up in such a way that they
remain closed at zero, i.e. a 1 signal on the PLC allows the brakes to open.
Note
In terms of its reactions, the alarm is the same as the Emergency Stop alarm (3000). For
internal reasons, the reboot delay time of the NCK can be slightly increased.
Activation
The reboot delay can be activated as follows:
MD10088 $MN_REBOOT_DELAY_TIME (reboot delay) > 0
The value that has been entered supplies the reboot delay time in seconds.
Evaluation with a system variable

System variable $AN_REBOOT_DELAY_TIME can be read in a synchronized action. A
value greater than zero indicates that the reboot request was initiated from the command
software and how much time (in seconds) the NCK waits until reboot (POWER OFF and
subsequent POWER ON). In a synchronized action, the user can identify the pending reboot
and appropriately respond (e.g. with "Safe Standstill" for a Safety Integrated application).
$AN_REBOOT_DELAY_TIME is 0.0 provided no reboot request from the command software
is pending.
Extended Functions
K3: Compensations
4.8 Data lists
4.8 Data lists
4.8.1 Machine data

10050 SYSCLOCK_CYCLE_TIME Basic system clock cycle
10070 IPO_SYSCLOCK_TIME_RATIO Factor for interpolator clock cycle
10082 CTRLOUT_LEAD_TIME Shift of setpoint transfer time
10083 CTRLOUT_LEAD_TIME_MAX Maximum permissible setting for shift of setpoint
transfer time
10088 REBOOT_DELAY_TIME Reboot delay
18342 MM_CEC_MAX_ POINTS[t] Maximum number of interpolation points of sag
compensation

20150 GCODE_RESET_VALUES Reset G groups

32450 BACKLASH Backlash
32452 BACKLASH_FACTOR Weighting factor for backlash
32456 BACKLASH_DYN Compensation value for the dynamic backlash
compensation
32457 BACKLASH_DYN_MAX_VELO Limitation of the dynamic backlash compensation
value change
32490 FRICT_COMP_MODE Type of friction compensation
32500 FRICT_COMP_ENABLE Friction compensation active
32510 FRICT_COMP_ADAPT_ENABLE Friction compensation adaptation active
32520 FRICT_COMP_CONST_MAX Maximum friction compensation value
32530 FRICT_COMP_CONST_MIN Minimum friction compensation value
32540 FRICT_COMP_TIME Friction compensation time constant
32550 FRICT_COMP_ACCEL1 Adaptation acceleration value 1
Extended Functions
K3: Compensations
4.8 Data lists

32580 FRICT_COMP_INC_FACTOR Weighting factor for friction compensation value for
short traversing motion
32610 VELO_FFW_WEIGHT Feedforward control factor for velocity/speed
feedforward control
32620 FFW_MODE Feedforward control mode
32630 FFW_ACTIVATION_MODE Activate feedforward control from program
32650 AX_INERTIA Inertia for torque feedforward control
32700 ENC_COMP_ENABLE Interpolatory compensation
32710 CEC_ENABLE Enabling of sag compensation
32711 CEC_SCALING_SYSTEM_METRIC System of units for sag compensation
32720 CEC_MAX_SUM Maximum compensation value for sag compensation
32730 CEC_MAX_VELO Change of velocity during sag compensation
32750 TEMP_COMP_TYPE Temperature compensation type
32760 COMP_ADD_VELO_FACTOR Velocity increase as a result of compensation
32711 CEC_SCALING_SYSTEM_METRIC System of units for sag compensation
32800 EQUIV_CURRCTRL_TIME Equivalent time constant current control loop for
feedforward control
32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant speed control loop for
feedforward control
32910 DYN_MATCH_TIME Time constant for dynamic response adaptation
36500 ENC_CHANGE_TOL Maximum tolerance for position actual value
switchover
38000 MM_ENC_COMP_MAX_POINTS Number of interpolation points with interpolatory
compensation
4.8.2 Setting data

41300 CEC_TABLE_ENABLE[t] Enable evaluation of beam sag compensation
table
41310 CEC_TABLE_WEIGHT[t] Weighting factor for beam sag compensation
table
Extended Functions
K3: Compensations
4.8 Data lists

43900 TEMP_COMP_ABS_VALUE Position-independent temperature compensation
value
43910 TEMP_COMP_SLOPE Gradient for position-dependent temperature
compensation
43920 TEMP_COMP_REF_POSITION Reference position for position-dependent
temperature compensation
4.8.3 Signals

NC Ready DB10.DBX108.7 DB2700.DBX2.7
4.8.3.2 Signals from mode group

Mode group ready DB11.DBX6.3 DB3100.DBX0.3

Channel ready DB21, ... .DBX36.5 DB3300.DBX4.5

Activate dynamic backlash compensation DB31, ... .DBX25.0 DB380x.DBX5001.0
Extended Functions
K3: Compensations
4.8 Data lists

Referenced/synchronized 1 DB31, ... .DBX60.4 DB390x.DBX0.4
Referenced/synchronized 2 DB31, ... .DBX60.5 DB390x.DBX0.5
Axis ready DB31, ... .DBX61.2 DB390x.DBX1.2
Dynamic backlash compensation active DB31, ... .DBX102.0 DB390x.DBX5006.0
Extended Functions
K5: Mode groups, channels, axis interchange 5
Mode group
A mode group is a collection of machine axes, spindles and channels which are programmed
to form a unit. In principle, a single mode group equates to an independent NC control (with
several channels). A mode group is made up of those channels that always have to operate
simultaneously in the same mode.
Note
There is one mode group as standard.
Reference:
Function Manual Basic Functions; Mode Group, Channel, Program Operation (K1)
Note
Only 1 mode group is available for SINUMERIK 828D.
Channels
Every channel has its own program decoding, block preparation and interpolation functions.
A part program can be processed independently within a channel.
Note
There is one channel available as standard.
Reference:
The processes in several channels of a mode group can be synchronized in the parts
programs.
Note
Only 1 channel is available for SINUMERIK 828D.
Extended Functions
K5: Mode groups, channels, axis interchange
5.2 Mode groups - only 840D sl
Axis/spindle interchange
After control system power ON, an axis/spindle is assigned to a specific channel and can
only be utilized in the channel to which it is assigned.
With the function "Axis/spindle interchange" it is possible to enable an axis/spindle and to
allocate it to another channel, that means to replace the axis/spindle.
Axis/spindle interchange can be activated via the parts program, via the PLC program and
from motion-synchronous actions.
Axis/spindle interchange is also possible via:
Programming in parts program GET/GETD.
Automatically through programming of axis name.
Without preprocessing stop and existing synchronization between preprocessing and
main run.
Through PLC via the VDI interface to the NCK.
Axis replacement extensions
Set axis replacement behavior variable.
Axis replacement with an axis container rotation with implicit GET/GETD.
Axis replacement without pre-processing stop of axes not involved in the contour.
Geometry axis with rotated frame (ROT) and axis replacement in JOG operational mode.
Axis replacement via synchronized actions GET(axis), AXTOCHAN.
Note
For SINUMERIK 828D, an axis/spindle interchange is not possible between channels.
5.2 Mode groups - only 840D sl
Mode groups
A mode group combines NC channels with axes and spindles to form a machining unit.
A mode group contains the channels that are required to run simultaneously in the same
mode from the point of view of the machining sequence.
Any axis can be programmed in any channel of a certain mode group. A mode group
therefore corresponds to an independent, multiple-channel NC.
Extended Functions
5.3 Channels - only 840D sl
example
On large machine tools (machining centers), it may be necessary for a part program to be
processed on one part of the machine while new workpieces to be machined need to be
clamped and set up on another part. Such tasks usually require two independent NC
controls.
With the mode group function, both tasks can be implemented on one NC control with two
mode groups because a different mode can be set for each mode group (AUTOMATIC mode
for the program processing, JOG for setting up a workpiece).
Mode group assignment

The configuration of a mode group defines the channels, geometry axes, machine axes and
spindles which it is to contain.
A mode group consists of one or several channels which must not be assigned to any other
mode group. Machine axes, geometry axes and special axes themselves are assigned to
these channels. A machine axis can only be assigned to the channels of one mode group
and can only traverse in this mode group.
A mode group is configured with the following data:
Channel-specific machine data:
MD10010 $MN_ASSIGN_CHAN_TO_MODE_GROUP (channel valid in mode group)
Configuration data of the channels
Note
For more information about the first mode group, please refer to:
References:
Function Manual, Basic Functions; Mode Group, Channel, Program Operation Mode
(K1),
Note
The terms Channel, Channel Configuration, Channel States, Effects of Commands/Signals,
etc. is described for the first channel in:
Reference:
For all other channels, this information applies, too.
Extended Functions
5.3.1 Channel synchronization (program coordination)
Function
For example, for double-slide machining or real-time actions, the possibility for the
synchronization of the machining between channels must be present. The channels affected
shall perform certain processing procedures time-matched.
To allow this machining, the relevant channels must be joined to form a synchronization
group (mode group).
The channel synchronization is made only with the NC language.
Preconditions
The relevant channels must belong to the same mode group.
Programming
There are special statements (commands) for the channel synchronization. In each case,
they are listed in one block.
Table 5- 1 Program coordination statements
Statement Meaning
INIT (<channel-no.>, <path specification>, Selection of a program for processing in a certain channel:
<acknowledgement mode>) <channel no.>: Number of channel
<path specification>: An absolute or relative path to the
NC program
<acknowledgement Acknowledgement mode:
mode>: N (without) or S (synchronous)
CLEAR (<program name>) Deletion of a program by indicating the program name.
START(<channel no.>, <channel no.>, ... ) Starting the selected programs in other channels.
<channel no.>, ...: Enumeration of the channel
numbers
WAITM (<marker no.>, <channel no.>, <channel no.>, ...) Unconditional wait: When a WAITM() call is reached, the
axes of the current channel are decelerated and a wait
made in the other channels to be synchronized until the
marker number specified in the call is reached. The group
is synchronized when the other channels are also
decelerated as they reach their WAITM() command. The
synchronized channels then continue operation.
<marker no.>: The tag number must be the same
in all channels.
<channel no.>, ...: Enumeration of the channel
numbers (the own channel does
not need to be specified).
Extended Functions
Statement Meaning
WAITE (<channel no.>, <channel no.>, ...) Waits for the end of program of the specified channels
(current channel not specified).
WAITMC (<marker no.>, <channel no.>, <channel no.>, ...) Conditional wait in path controlled operation for the
specified wait marker from the specified channels. The
current channel can be specified, but this is optional.
When processing continues after the wait marks from the
other channels in the group have arrived, the wait marks of
these channels are deleted.
SETM (<marker no.>, (<marker no.>, ...) Set the wait markers for conditional wait with WAITMC() for
the channel specified in the SETM(). The channel thus
declares its wait characteristics for the partner channels as
fulfilled.
The command can be activated in synchronized actions.
Up to 10 marks (0-9) can be set using one command.
CLEARM (<marker no.>, (<marker no.>, ...) Cleat the wait markers for conditional wait with WAITMC()
for the channel specified in the CLEARM(). The channel
thus declares to its partner channels that its wait
characteristic is fulfilled.
The command can be activated in synchronized actions.
Up to 10 marks (0 - 9) can be deleted using one command.
Note
For further information about WAITMC and SETM, see Section "Channel synchronization:
Conditional wait in path controlled operation (Page 311)".
Note
A maximum of 100 markers (marker 0 ... 99) are available in a multi-channel system.
A single-channel system only has marker 0.
Example: Unconditional wait with WAITM

Channel 1: Program /_N_MPF_DIR/_N_MPF100_MPF is selected.

N10 INIT(2,"MPF200","N")
N11 START(2)
... ; Machining in channel 1
N80 WAITM(1,1,2) ; Wait until wait marker 1 is reached in channels 1
and 2.
... ; Additional machining in channel 1.
N180 WAITM(2,1,2) ; Wait until wait marker 2 is reached in channels 1
and 2.
Extended Functions

N200 WAITE(2) ; Wait for the end of program of channel 2
N201 M30 ; End of program of channel 1, total end.
Channel 2: The INIT command (see N10 in _N_MPF100_MPF) selects the

_N_MPF200_MPF program for execution in channel 2.

;$PATH=/_N_MPF_DIR
... ; Machining in channel 2
N70 WAITM(1,1,2) ; Wait until wait marker 1 is reached in channels 1 and 2.
N270 WAITM(2,1,2) ; Wait until wait marker 2 is reached in channels 1 and 2.
N400 M30 ; End of program in channel 2.
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Extended Functions
5.3.2 Channel synchronization: Conditional wait in path controlled operation
Function
For the conditional wait with WAITMC, deceleration and waiting is made only when not all
channels to be coordinated have set their marker numbers for a synchronization.
The instants in time for generating wait marks and the conditional wait calls are decoupled.
Note
Markers can also be set for notification between channels when deceleration and waiting is
not planned (no WAITMC command). In this case, the markers of the channel receive their
values via Reset and NC Start.
Requirements
To use the conditional wait with WAITMC with reduced wait times:
G64 path controlled operation must be set.
The "LookAhead" function must be active.
Note
If exact stop (G60, G09) is selected, waiting with WAITMC() corresponds to waiting with
WAITM().
Braking behavior
Starting with the motion block before the WAITMC() call, the wait markers of the other
channels to be synchronized are checked. If these are already available, machining
continues without braking (no wait):
Y
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Figure 5-1 Change of the path velocity for the conditional waiting with WAITC: Wait markers for all
channels already available
Extended Functions
If the wait marker for a channel to be synchronized is missing, braking will be started. During
braking, a check is made in each interpolation cycle whether the still missing wait markers
for the channels to be synchronized have arrived in the meantime. In this case, a further
acceleration to the path velocity is made and machining continues:
Y
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Figure 5-2 Change of the path velocity for the conditional waiting with WAITC: The last wait marker
arrives during the braking
If the path velocity has been braked to zero before the expected markers of the channels to
be synchronized have arrived, the machining stops until the missing markers have arrived.
When the last expected marker arrives, acceleration resumes from standstill to the path
velocity:
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Figure 5-3 Change of the path velocity for the conditional waiting with WAITC: The last wait marker
arrives after the braking
Block change in the braking ramp

If the IPOBRKA (block change possible in the braking ramp) motion criterion is active, the
arrival of the wait marker causes an instantaneous switch to the next block and the axes
started.
If the marker has not yet been reached or some other motion criterion prevents the block
change, braking continues.
Extended Functions
Example: Conditional wait in path controlled operation

The example is schematic and shows only those commands that are relevant to the
synchronization process.
Channel 1:

%100
N10 INIT(2, "_N_200_MPF","n") ; Select partner program channel 2.
N11 INIT(3,"_N_300_MPF","n") ; Select partner program channel 3.
N15 START(2,3) ; Start programs in channel 2, 3.
... ; Machining in channel 1.
N20 WAITMC(7,2,3) ; Conditional wait for marker 7 from channels
2 and 3.
... ; Further machining in channel 1.
N40 WAITMC(8,2) ; Conditional wait for marker 8 from channel
2.
N70 M30 ; End channel 1.
Channel 2:

%200
N200 ; Machining in channel 2.
N210 SETM(7) ; Channel 2 sets wait marker 7.
N250 SETM(8) ; Channel 2 sets wait marker 8.
Channel 3:

%300
...
N350 WHEN <condition> DO SETM(7) ; Set wait marker in a synchronous
action.
Extended Functions
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Figure 5-4 Conditional wait in path controlled operation with three involved channels (schematic)
Example: WAITMC and read-in disable

M555 is output in channel 3 while the axis is traversing and generates a read-in disabled
(RID). Because the WAITMC is added to block N312, the wait marker is set and channel 2
continues to travel. The read-in disable causes the program processing in channel 3 to stop.
Note
For active G64, a WAITMC(...) block does not create its own block but is added to the
previous block. A drop in velocity must be prevented when continuous-path mode is active. A
WAITMC is therefore fulfilled if the preceding block is halted, e.g. by a read-in disable.
Extended Functions
Channel 2:

N112 G18 G64 X200 Z200 F567 ; Machining in channel 2.
N120 WAITMC(1,2,3) ; Conditional wait for marker 1 from channels 2
and 3.
... ; Further machining in channel 2 because the
WAITMC is added to block N312.
Channel 3:
Comment
; During travel, M555 read-in disable.
N312 G18 G64 D1 X180 Z300 M555
N320 WAITMC(1,2,3) ; Wait because of ELSP.
5.3.3 Running-in channel-by-channel
Function
For multi-channel systems, using the function "channel-by-channel running-in", the part
program of a selected channel can be actually tested at the machine. The other channels are
then in the "program test" state. This means that when starting all channels, only the axes of
the selected channel are actually traversed.
In addition, for individual axes/spindles, whose channel is in the "program test" state, users
have the option of suppressing the "program test" state and actually operating these
axes/spindles together with those of the selected channel.
Advantage
For multi-channel systems, generating part programs places high demands on the ability of
the programming engineer to think in abstract terms. By using the function "channel-by-
channel running-in", testing these part programs can be more selectively arranged with less
associated risk.
Application
The function "channel-by-channel running-in" is used for:
Multi-channel systems
Machines with POSA or command axis motion
Extended Functions
Sequence
Multi-channel systems are either started at the same time or staggered in time, channel for
channel. As an alternative, the PLC can start a channel and its part program initializes and
starts the channels. The function "channel-by-channel running-in" supports both of these
versions. As a consequence, a channel group is obtained, which should operate together.
Normally, this group comprises all of the channels of the NCK being used.
Generally, a channel moves a tool adapter in the machining space and therefore the tool.
Several channels each move a tool in the same machining space and therefore require
(mandatory) synchronization between the channels in order to avoid collisions and to
organize how they operate with one another. The following synchronizations are
conceivable:
Channel coordination via the part program commands WAITM, WAITMC, WAITE, START.
Channel synchronization via the PLC.
Example:
In channel 1, M107 is kept with the read-in disable until channel 2 has reached M207 and
vice versa.
Axis interchange, i.e. a channel waits until the other channel relinquishes the axis.
Freely programmed synchronization using global variables in the part program.
Cross-channel couplings
Axis container rotation
Testing the program including the parallel synchronized actions in the main run and
synchronization of the synchronized actions with the channel.
Under these general conditions, it is almost impossible to just start one channel - it would
remain stationary at the first synchronization location.
Using the function "channel-by-channel running-in" all channels of the group are to be
started, and only a few channels, generally just one channel, actually physically moves its
axes. The other channels are then in the "program test" state.
This is the reason why users must define the channels in which they do not want any motion.
This is made from the user interface in the "Program controls" menu. When selected, the
following channel-specific signal is set in the HMI/PLC interface:
DB21, ... DBX25.7 (program test selected)
The activation is then made using the channel-specific NC/PLC interface signal:
DB21, ... DBX1.7 (activate program test)
The following interface signal is set in the PLC as checkback signal:
DB21, ... DBX33.7 (program test active)
Further, for a successful operation, it may be necessary that several axes/spindles -
especially spindles - are actually physically operated, although their channel is in the
"program test" state. The following NC/PLC interface signal is used for this purpose:
DB31, ... DBX14.0 (suppress program test)
Extended Functions
Example:
A system comprises a main spindle and counterspindle. Two slides can operate on both the
main spindle and counterspindle. Each slide is controlled from a separate channel. The main
spindle is in channel 1, the counterspindle in channel 2. Channel 1 is tested and channel 2 is
disabled using the channel-specific NC/PLC interface signal DB21, ... DBX1.7 (activate
program test). The two workpiece spindles - main spindle and counterspindle - play
somewhat of a "special role". A workpiece can be machined, without having to absolutely
traverse the workpiece spindle in real terms in the channel. This is the reason why it is
necessary that both workpiece spindles or both workpiece spindle aggregates actually move
in real terms (where relevant, including axes at the workpiece).
Note
The "program test" state can only be activated/deactivated in the stopped channel state.
However, the axis-specific NC/PLC interface signal "suppress program test" can always be
activated.
Diagnostics
The "program test" state can be interrogated using system variables:
For the display in the user interface, in synchronized actions or with a preprocessing stop
in the part program via the system variables:
$AC_ISTEST "Program test" state for the channel

Supplies TRUE (1), if the "program test" state for the channel is
active.
$AA_ISTEST[<n>] "Program test" state for the axis <n>
Supplies TRUE (1), if the "program test" state for axis <n> is active.
Without preprocessing stop in the part program via the system variable:
$P_ISTEST Supplies TRUE (1), if the "program test" state for the channel is
active.
Example:
The channel runs under "program test" and axis "C" was withdrawn using "suppress program
test". A query using system variables then supplies the following result:
$AC_ISTEST = TRUE
$P_ISTEST = TRUE
$AA_ISTEST[C] = FALSE
Extended Functions
Boundary conditions
Axis replacement
The function "axis interchange" allows that an axis/spindle is known in several channels and
can be programmed from this alternating (see Section "Axis/spindle replacement
(Page 320)").
In conjunction with the functions "program test" and "channel-by-channel running-in", the
following must be observed for an axis interchange:
If only one of the channels is in the "program test" state, then the interchanged axis is
taken from this channel and is inserted in a channel that is not in the "program test" state.
For an interchanged axis with active axis disable, for a change via the channels
with/without channel state "program test", then the state in the axis itself does not change
(see example 3).
For a program test, for end of part program/reset, for all axes/spindles that do not
interpolate, resynchronization is made at the actual servo position. As a consequence, for
an axis interchange that is first made after the end of the program, as the axis may only
exit the channel at the end of the program, the simulated position reached is not
transferred to the accepting channel.
Note
The programs should also include a WAIT tag at the end in order that they are
simultaneously exited.
Examples
Example 1: Channel 2 is to be tested in a 3-channel system.
The following program test sequences are possible:
a) Program test without SERUPRO
1. The user decides which axes/spindles should actually be physically traversed. "Suppress
program test" is set for these axes.
2. The "program test" state is selected for channels 1 and 3.
3. Channels 1, 2 and 3 are started via the PLC.
4. "Program test" can be selected again after the end of the program.
5. If the actual setting of "suppress program test" is also practical for other situations
(channel 1 or channel 3 are to be tested), then this signal can remain set. This is certainly
practical in many cases.
b) Program test with SERUPRO

1. The user decides which axes/spindles should actually be physically traversed. "Suppress
program test" is set for these axes.
2. The "program test" state is selected for channels 1 and 3.
3. Channels 1, 2 and 3 are started via the PLC.
4. A fault or an alarm occurs, the user interrupts with RESET.
Extended Functions
5. SERUPRO at the interruption location of all 3 channels.

6. Search destination has been reached in all 3 channels.
7. Start all 3 channels.
8. Channels 1 and 3 are now again in "program test" and "channel-by-channel running-in" is
continued.
Example 2: Activating "suppress program test"

A channel is in program test. In operation, "suppress program test" should be initiated for
axis "Y" (at block N1010).

N1000 G0 Y1000
N1010 G4 F10
N1020 G0 G91 Y=10 ; Incremental traversing.
N1030 M30
With this sequence, the program moves to position 1010, i.e. the simulated component
"1000" of this axis is moved after activating "suppress program test".
Example 3: Program test and axis interchange

In the following example, axes "X" from channel 1 and "X1" from channel 2 define the 1st
axis of the NCK. At the start, all axes are at position 0.
Channel 1 with "Program test" Channel 2 without "Program test"

N10010 G0 X0 Y0
N10020 X100
N10030 WAITM(91,1,2)
N10040 WAITM(92,1,2)
N10050 M0
N10060 M30
N20010 WAITM(91,1,2)
N20020 G91 G0 X1=10
N20030 WAITM(92,1,2)
N20040 M0
N20050 M30
With block N20040 (M0) the 1st axis (X or X1) is physically located at position 110! This
means that the simulated position reached in channel 1 of "100" is assumed in channel 2
with block N20020.
References
For information on the program test, see:
Function Manual Basic Functions; K1: Mode Group, Channel, Program Operation, Reset
Response
Extended Functions
5.4 Axis/spindle replacement
5.4.1 Introduction
General information
An axis/a spindle is permanently assigned to a specific channel via machine data. The
axis/spindle can be used in this channel only.
Definition
With the function "Axis or spindle replacement" it is possible to enable an axis or a spindle
and to allocate it to another channel, that means to replace the axis/spindle.
Since the spindle function is subordinated to the axis function, only the term "Axis
replacement" is used in the following.
Axis types
According to the channel, we distinguish four types of axes: The reactions at axis change
depend on the settings in MD 30552:
MD30552 $MA_AUTO_GET_TYPE
Channel axis
A channel axis can be programmed in the part program and traversed in all modes.
PLC axis
A PLC axis can only be positioned via the PLC.
If a PLC axis is programmed in the part program
in case of MD AUTO_GET_TYPE = 0 an alarm will be output.
in case of MD AUTO_GET_TYPE = 1 an automatic GET will be generated.
in case of MD AUTO_GET_TYPE = 2 an automatic GETD will be generated.
Neutral axis
If a neutral axis is programmed in the part program
Extended Functions
Axis in another channel

This is actually not a proper type of axis. It is the internal state of a replaceable axis. If this
happens to be active in another channel (as channel, PLC or neutral axis).
If an axis is programmed in another channel in the part program:
Note
Both machine data:
MD20110 $MC_RESET_MODE_MASK
MD20112 $MC_START_MODE_MASK
control the behavior of axis assignments in RESET, during booting and part program
start. The settings for channels between which axes are to be replaced must be selected
such that no illegal constellations (alarms) are generated in conjunction with the following
machine data:
MD30552 $MA_AUTO_GET_TYPE
References:
Function Manual, Basic Functions; Axes, Coordinate Systems, Frames (K2), Section:
Workpiecerelated actualvalue system
Requirements
In order for an axis replacement to be executed, the valid channel for the machine axis
number must be specified via the channel-specific machine data
MD20070 $MC_AXCONF_MACHAX_USED (machine axis number valid in channel)
and the delete setting of the channel for axis replacement via the axis-specific
MD30550 $MA_AXCONF_ASSIGN_MASTER_CHAN (channel for axis replacement).
This results in the following regulations:
1. In which channel can the axis be used and replaced?
2. To which channel shall the axis be allocated with power ON?
Extended Functions
Example of an axis replacement between channels

With 6 axes and 2 channels, the 1st, 2nd, 3rd and 4th axis in channel 1 and the 5th and 6th
axis in channel 2 shall be used. It shall be possible to replace the 1st axis, this shall be
allocated to channel 2 after power ON.
The channel-specific machine data must be allocated with:
CHANDATA(1)
MD20070 $MC_AXCONF_MACHAX_USED=(1, 2, 3, 4, 0, 0, 0, 0)
CHANDATA(2)
MD20070 $MC_AXCONF_MACHAX_USED=(5, 6, 1, 0, 0, 0, 0, 0)
The axis-specific machine data must be allocated with:
MD30550 $MA_AXCONF_ASSIGN_MASTER_CHAN[AX1]=2
Display
The current axis type and the current channel responsible for this axis are displayed in an
axial PLC interface byte (see Section "Axis replacement via the PLC").
Note
If an axis is not valid in the selected channel, this is indicated by inverting the axis name on
the user interface.
5.4.2 Example of an axis replacement
Assumption
With 6 axes and 2 channels, the 1st, 2nd, 3rd and 4th axis in channel 1 and the 5th and 6th
axis in channel 2 shall be used. It shall be possible to replace the 2nd axis between the
channels and to allocate to channel 1 after power ON.
Exercise
The task is subdivided into the following areas:
Machine data allocation so that the prerequisites for axis replacement are given.
Programming of axis replacement between channel 1 and channel 2.
Fulfillment of preconditions
Population of channel-specific machine data MD20070
$MC_AXCONF_MACHAX_USED[1]=(1, 2, 3, 4, 0, 0, 0, 0)
$MC_AXCONF_MACHAX_USED[2]=(5, 6, 2, 0, 0, 0, 0, 0)
Extended Functions
Population of the axis-specific machine data:

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5.4.3 Axis replacement options

One or more axes/spindles can be activated for replacement between channels by the part
program or by motion-synchronous actions. An axis/spindle replacement can also be
requested and released from the PLC via the VDI interface. The axis/spindle must have
been released in the current channel and will be taken over by the other channel with the
GET command and released with the RELEASE command.
If the specified conditions are met, an axis/spindle replacement is initiated by:
Programming in part program GET/GETD
Take over an axis or a spindle from another channel with GET or get it from another
channel with GETD. With GETD a corresponding release is not required.
Automatic by programming of the axis name, if the required conditions have been met by
MD30552 $MA_AUTO_GET_TYPE > 0.
Without preprocessing stop and existing synchronization between preprocessing and
main run.
Through PLC via the VDI interface to the NCK.
When taking over a PLC-controlled axis, the channel behavior triggered by the NC program
can be de-coupled via an interface signal. This permits, for example, individual PLC axes to
be interpolated independently of the NC program (see also Section "Autonomous singleaxis
operations (Page 608)").
Axis replacement extensions

Setting axis replacement behavior as variable via machine data MD10722
$MN_AXCHANGE_MASK.
Axis replacement with an axis container rotation with implicit GET/GETD
Axis replacement without pre-processing stop of axes not involved in the contour.
Extended Functions
Geometry axis with rotated frame and axis replacement in JOG mode via machine data
MD32074 $MA_FRAME_OR_CORRPOS_NOTALLOWED can be activated.
Axis replacement via synchronized actions GET(axis), RELEASE(axis), AXTOCHAN,
$AA_AXCHANGE_TYP(axis).
5.4.4 Replacement behavior NC program
Possible transitions
The following diagram shows which axis replacement possibilities are available.
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Figure 5-5 Transitions of possible axis states during axis replacement
Extended Functions
5.4.5 Transition the axis into the neutral state (RELEASE)
Function
The predefined RELEASE() procedure is used to bring an axis/spindle into the "Neutral axis"
state.
Syntax
RELEASE(<MA>, SPI(<SPNR>)[, ...])
Meaning
RELEASE: Axis/spindle brought into the "Neutral axis" state

Supplementary condition: Must be alone in the block.
MA: Machine axis name
SPI(...): Function to convert a spindle number into the appropriate axis name
SPNR: Spindle number
More information
General abort conditions

Not all the requirements for the axis replacement have been met. See machine data
MD20070 $MC_AXCONF_MACHAX_USED
MD30550 $MA_AXCONF_ASSIGN_MASTER_CHAN)
The axis is involved in a transformation.
The axis belongs to an axis grouping.
Abort with reset

If a reset is triggered when an axis has been released with RELEASE(), but has not yet been
taken over by means of GET(), the axis is re-assigned to the releasing channel.
Guide axis of a gantry grouping

If the guide axis of a gantry grouping is released, all synchronous axes are also released.
Extended Functions
5.4.6 Transferring an axis or spindle into the part program (GET, GETD)
Options
The release time and the behavior of an axis or spindle replacement is influenced in the part
program as follows:
Programming with the GET command in the same channel.
Directly from another channel through programming with GETD.
References:
Programming Manual Job Preparation; Flexible NC Programming,
Section: Axis replacement, spindle replacement (RELEASE, GET, GETD)
With the GETD command

GET (axis name, axis name, SPI (spindle no.), ...)
The takeover of an axis is delayed if
the axis is changing the measuring system.
servo disable is being processed for the axis (transition from control in follow-up/stop and
vice versa).
the axis/spindle disable is set.
the axis has not yet been enabled by the other channel with RELEASE.
interpolation for the axis has not yet been completed (except for a speed-controlled
spindle).
With GET (axis name, ...) a separate NC block with pre-processing stop is always generated.
Exceptions:
If the axis is already a channel axis, then no block is generated.
If the axis is synchronous, (i.e. it has not been swapped to another channel in the
meantime or received a signal from the PLC) no extra block is generated either.
Extended Functions
With the GETD command

With GETD (GET Directly) an axis is fetched directly from another channel. That means that
no suitable RELEASE must be programmed for this GETD in another channel. In addition,
another channel communication must be created (e.g. wait marks), since the supplying
channel is interrupted with GETD. If the axis is a PLC axis, replacement is delayed until the
PLC has enabled the axis.
CAUTION
Function-less axis
The GETD command interrupts the program run in the channel in which the required axis is
currently to be found! (REORG).
Exception: The axis is at the time in a neutral state.
Note
If the GET or GETD command has been programmed, take-over is delayed and the channel
is reset; the channel will no longer try to take over the axis.
An axis taken over with GET remains allocated to this channel even after a key RESET or
program RESET. The axis can be replaced by programming RELEASE and GET again or
will be assigned to the channel defined in the following machine data during POWER ON:
MD30550 $MA_AXCONF_ASSIGN_MASTER_CHAN
5.4.7 Automatic axis replacement
Automatically through programming of axis name

Depending on machine data MD30552 $MA_AUTO_GET_TYPE a GET or GETD is
generated automatically if a neutral axis is again programmed or assigned to another
channel.
Preconditions for automatic axis replacement

MD30552 $MA_AUTO_GET_TYPE > 0 must be true for automatic axis replacement.
Extended Functions
Automatic GETD
Note
If an automatic GETD is set, the following must be observed:
Channels could mutually influence each other.
(REORG, when axis is removed.)
With simultaneous access of several channels to an axis it is not known which channel
will have the axis at the end.
Example 1

N1 M3 S1000
N2 RELEASE (SPI(1)) ; => Transition to neutral condition
N3 S3000 ; New speed for released spindle
; MD AUTO_GET_TYPE =
; 0 =>Alarm "Wrong axis type" is generated
; 1 => GET (SPI(1)) is generated.
; 2 => GETD (SPI(1)) is generated.
Example 2

; (axis 1 = X)
N1 RELEASE (AX1 ; => Transition to neutral condition
N2 G04 F2
N3 G0 X100 Y100 ; Motion of the released axis
; 1 => GET (AX1) is generated.
; 2 => GET (AX1) is generated.
Example 3

; (axis 1 = X)
N1 RELEASE (AX1) ; => Transition to neutral condition
N2 G04 F2
N3 POS (X) = 100 ; Positioning of the released axis
; 1 => GET (AX1) is generated. *)
; 2 => GET (AX1) is generated. *)
*) If the axis is still synchronized, no dedicated block will be generated.
Extended Functions
5.4.8 Axis replacement via PLC

The PLC can request and traverse an axis at any time and in any operating mode.
The PLC can change an axis from one channel into the other channel (only for 840D sl).
TYPE display
The type of an axis can be determined at any time via an interface byte (PLC-axis, channel
axis, neutral axis).
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Extended Functions
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change. Also for a channel interchange with GET and RELEASE (only 840D sl).
Controlling PLC axes/spindles for 840D sl

PLC axes and PLC spindles are traversed using function block FC18 in the basic PLC
program
FC18: SpinCtrl Spindle control
Extended Functions
Examples
The sequence of NC/PLC interface signals to change an NC axis to a PLC axis and to
transition an NC axis into a neutral axis by the PLC are shown in the following diagrams.
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Extended Functions
5.4.9 Set axis replacement behavior variable.

The axis is replaced in the currently enabled channel and, depending on the respective axis
type, the axis replacement behavior can be influenced via machine data MD10722
$MN_AXCHANGE_MASK:
Table 5- 2 Time of release of axes or spindles during replacement
MD10722 Axis replacement behavior

Bit 0 = 1 Automatic Axis Replacement between two channels also takes place when the axis has
been brought to a neutral state by WAITP.
Bit 1 = 1 Release by Axis Container Rotation with implicitly generated GET/GETD
When requesting an axis container rotation, all axes of the axis container that can be
assigned to the executing channel are taken into the channel by means of an implicit
GET or GETD. A subsequent replacement is only allowed after completion of the axis
container rotation.
Bit 2 = 1 Axis replacement without pre-processing and possible forced re-organization of axes
not involved in the contour.
When an intermediate block is inserted in the main run, a check will be made to
determine whether or not reorganization is required. Reorganization is only necessary if
the axis states of this block do not match the current axis states.
Bit 3 = 0 PLC replacing of permanently assigned PLC axis
An axis replacement can be requested from the PLC for each axis. The permanently
assigned PLC axis only from neutral axis to PLC axis and vice versa.
Bit 3 = 1 Replacement request via VDI interface
A replacement request via VDI interface is only executed for an:
axis exclusively controlled by the PLC when
MD30460 $MA_BASE_FUNCTION_MASK with Bit4=1.
permanently assigned competing positioning axis (PLC axis) when
MD30460 $MA_BASE_FUNCTION_MASK with Bit5=1.
For such axes the interface signal NCK PLC DB31, ... DBX68.5 (replacement
possible) is always set to 1. For all other axes this bit is set to 0. For a permanently
assigned PLC axis an axis replacement is only possible from neutral axis to PLC axis
and vice versa.
Extended Functions
5.4.10 Axis interchange via axis container rotation
Enabling axis container rotation

When an axis container rotation is enabled, all container axes that can be allocated to a
channel are allocated to this channel using implicitly generated GET or GETD. An axis can only
be relinquished, e.g. to another channel, after container rotation.
Note
The implicit assignment of an axis to a channel is notpossible if the axis in the state "main
run axis" (e.g. is a PLC axis). In order to be able to participate in the axis container rotation,
the axis must first exit the state.
For further explanations on the axis replacement of container axes (see Section "B3:
Distributed systems - 840D sl only (Page 71)").
Example: Axis container rotation with an implicit GET or GETD
Action Channel 1 Action Channel 2

SPOS = 180 positioned
AXCTSWE(CT 1)
; gets spindle in Channel 1
; and allows axis container rotation
Assumption:
The spindle is used in both channels and is also an axis in axis container CT 1.
Activation
Axis interchange using axis container rotation and implicit GET/GETD is activated using
machine data MD10722 $MN_AXCHANGE_MASK, bit 1=1.
5.4.11 Axis replacement with and without preprocessing stop
Axis replacement extension without preprocessing stop

Instead of a GET block with a preprocessing stop, this GET request only generates an
intermediate block. In the main run, when this block is executed, the system checks whether
the states of the axes in the block match the current axis states. If they do not match, forced
reorganization can be triggered.
The following states of an axis or positioned spindle are checked for:
The mode, either for the axis or for positioned spindle
Setpoint position
Extended Functions
The following states of a Spindle in speed mode are checked:

Spindle mode: Speed mode
Spindle speed S
Direction of rotation M3, M4
Gear stage M40, M41, M42, M43, M44, M45
Master spindle at constant cutting rate.
In some instances, forced reorganization may be possible. Reorganization of the following
axes is forced in any case.
Activation
Replacement without preprocessing and checking of the current states is activated with
machine data MD10722 $MN_AXCHANGE_MASK, Bit 2=1.
Example
Activating an axis replacement without a preprocessing stop
N010 M4 S1000
N011 G4 F2
N020 M5
N021 SPOS=0
N022 POS[B]=1
N023 WAITP(B) ; Axis b becomes the neutral axis
N030 X1 F10
N031 X100 F500
N032 X200
N040 M3 S500
N041 G4 F2
N050 M5
N099 M30
If the spindle (axis B) is traversed immediately after block N023 as a PLC axis to 180 and
back to 1, and then again to the neutral axis, block N040 does not trigger a preprocessing
stop nor a reorganization.
Special case: Axis replacement with preprocessing stop

Without a GET or GETD instruction having previously occurred in the main run, the spindle
or the axis can be made available again by RELEASE (axis) or WAITP (axis), for example. A
subsequent GET leads to a GET with a preprocessing stop.
Extended Functions
5.4.12 Axis exclusively controlled from the PLC
Function
After the control boots, the axis is in the "neutral axis" state. The PLC controls it. To traverse
the axis as competing positioning axis (from the PLC via function block FC18), the axis must
first be explicitly requested from the PLC.
Note
Per machine data, the axis interchange to the PLC can be exclusively restricted to PLC
controlled axes: MD10722 $MN_AXCHANGE_MASK, Bit 3 = 1
The axis cannot be traversed from an NC part program.
Parameterizing an axis as axis that is exclusively controlled from the PLC is realized using
the axis-specific machine data:
MD30460 $MA_BASE_FUNCTION_MASK, Bit 4 = 1
Control by PLC
The traversing behavior of an axis exclusively controlled from the PLC is only influenced by
the axial NC/PLC interface signals:
DB31, ... DBX28.1 (reset)
DB31, ... DBX28.2 (continue)
DB31, ... DBX28.6 (stop along braking ramp)
Possible traversing functions

The following traversing functions are possible for axes exclusively controlled from the PLC:
1. Traversing in the JOG mode using the traversing keys and handwheel
2. Referencing the axis
3. Traversing as command axis via static synchronized actions
4. Traversing as asynchronous oscillating axis
5. Traversing as competing positioning axis from the PLC via FC18
After traversing functions 1. to 4. have been completed, the axis automatically goes back into
the "neutral axis" state. After traversing function 5. from the PLC has been completed, the
axis remains in the state "PLC axis". The axis only changes into the "Neutral axis" state after
having been explicitly released by the PLC.
Extended Functions
5.4.13 Axis permanently assigned to the PLC
Function
After the control has booted, the axis is in the "neutral axis" state and is controlled from the
NC channel. To traverse the axis as competing positioning axis (from the PLC via function
block FC18), the axis does not have to be explicitly requested from the PLC. Axis
interchange to the PLC is realized automatically using the traversing request via FC18. After
the traversing motion requested via FC18 has been completed, the axis again automatically
changes into the "neutral axis" state.
After the axis has been interchanged, and after the request from the PLC, the axis can also
be controlled from the PLC: "PLC axis" state.
Note
Per machine data, the axis interchange to the PLC can be exclusively restricted to axes that
are permanently assigned to the PLC: MD10722 $MN_AXCHANGE_MASK, Bit 3 = 1
Parameterizing an axis as axis that is permanently assigned to the PLC is realized using the
axis-specific machine data:
MD30460 $MA_BASE_FUNCTION_MASK, Bit 5 = 1
Control by the PLC or NC channel

The traversing behavior of an axis permanently assigned to the PLC can either be influenced
by the NC channel or by the PLC:
NC channel: Channel-specific NC/PLC interface signals (selection)
DB21, ... DBXDBX7.1 (NC start)
DB21, ... DBXDBX7.3 (NC stop)
DB21, ... DBXDBX7.7 (reset)
PLC: Axial NC/PLC interface signals
Extended Functions
Possible traversing functions

The following traversing functions are possible for an axis permanently assigned to the PLC:
1. Traversing in the JOG mode using the traversing keys and handwheel
2. Referencing the axis
3. Traversing as competing positioning axis from the PLC via FC18
After traversing functions 1. to 3. have been completed, the axis automatically goes back into
the "neutral axis" state.
5.4.14 Geometry axis in rotated frame and axis replacement
Replacement expansion via Frame with Rotation

In JOG mode, a geometry axis with rotated frame can be traversed as PLC axis or as a
command axis via static synchronized actions. In order to achieve this, in machine data
MD32074 $MA_FRAME_OR_CORRPOS_NOTALLOWED, bit 10=1 must be set. The
reposition behavior of this axis is influenced via Bit 11.
Note
Before changing operational mode during JOG mode
Before changing the operational mode from JOG mode, all traverse motions of all PLC and
command axes, which have been linked as geometry axes in the rotated frame, must have
been concluded. These axes must at least have become neutral axes again, otherwise alarm
16908 will be generated when the operational mode is changed. This alarm is also
generated when only a single geometry axis is traversed as a PLC or command axis in the
rotated coordinate system.
Such an axis can only become a PLC or command axis within the channel, an axis
replacement in another channel is not allowed.
Prerequisite for changing from JOG to AUTOMATIC

When changing from JOG mode to AUTOMATIC, the Condition program is interrupted and
the end point of this geometry axis motion is only taken over if in MD 32074:
FRAME_OR_CORRPOS_NOTALLOWED bit 11=1. This positions the PLC or command
axes in relation to the rotation of the frame.
All axes influenced by a rotating frame are considered as geometry axes grouping and are
handled collectively. In this way, all axes of the
assigned to the NC program or
all axes are neutral or
are active as main run axes (PLC, command, or oscillation axis).
Extended Functions
For example, if one axis is programmed with a WAITP, waiting is performed for all further
axes of the geometry axis grouping, so that these axes can collectively become neutral axes.
If one of the axes becomes a PLC axis in the main run, then all other axes of this grouping
become neutral axes.
If MD32074 $MA_FRAME_OR_CORRPOS_NOTALLOWED, bit 10 == 0 and ROT Z45 is
programmed in the NC program, then for the X and Y axes no axis interchange is possible.
This is also analogously valid for the Z axis for e.g. ROT X45 or ROT Y45 and also in the JOG
operating mode if a block was interrupted with this type of programming. Although in this
case the NC/PLC interface signals are set for the X and Y axes:
DB31, ...DBX68.5 (axis interchange possible) = 1
DB32, ...DBX68.5 (axis interchange possible) = 1
However, these are reset.
Only if MD32074 $MA_FRAME_OR_CORRPOS_NOTALLOWED, Bit 10 == 1 and no block
with this programming is being currently traversed, then in the JOG mode, these types of
axes can be interchanged.
5.4.15 Axis replacement from synchronized actions
Function
An axis can be requested with GET(axis) and be released for axis replacement with
RELEASE(axis) with a synchronous action.
Note
The axis must be assigned as a channel axis via machine data.
An axis can be transferred directly between channels to a certain channel with the NC
language command AXTOCHAN via synchronized actions or in the part program. This axis
does not have to be the same channel and it is not necessary that this channel be in
possession of the current interpolation right for the axis.
Extended Functions
Current state and interpolation right of the axis

With which axis type and interpolation right a possible axis replacement is to be performed,
can be deducted from the system variable $AA_AXCHANGE_TYP[axis].
0: The axis is assigned to the NC program
1: Axis assigned to PLC or active as command axis or oscillating axis
2: Another channel has the interpolation right.
3: Axis is neutral axis.
4: Neutral axis is controlled by the PLC.
5: Another channel has the interpolation right, axis is requested for NC program.
6: Another channel has the interpolation right, axis is requested as neutral axis.
7: Axis active for PLC or as command or oscillating axis, axis is
requested for PLC program.
8: Axis active for PLC or as command or oscillating axis, axis is
requested as neutral axis.
9: Permanently assigned PLC axis, in state of neutral axis.
10: Permanently assigned PLC axis, controlled by PLC, in state of neutral axis.
Permanently assigned PLC axis
in state of neutral axis $AA_AXCHANGE_TYP = 9 and
controlled by PLC, in state of neutral axis $AA_AXCHANGE_TYP = 10
will be assigned to PLC independently of GET and RELEASE permanently.
Whether the axis can also be replaced is displayed via the system variable
$AA_AXCHANGE_STAT[axis].
Extended Functions
State transitions GET, RELEASE from synchronous actions and when GET is completed
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Figure 5-9 Transitions from synchronized actions
For more information, please refer to:

References:
Function Manual, Synchronized Actions; Section: Actions in synchronized actions
Extended Functions
5.5 Marginal conditions
5.4.16 Axis interchange for leading axes (gantry)
Function
A closed gantry grouping is treated regarding its axes always as a unit regarding axis
interchange. This is the reason why for an axis interchange of the leading axis, an axis
interchange is simultaneously made for all synchronous axes of the gantry grouping. In
addition to the preconditions for the leading axis described in the previous chapters, the
appropriate preconditions must also be fulfilled for all synchronous axes of the gantry
grouping.
Axial machine data

For an axis interchange, the following axial machine data must be set the same for all axes
of a closed gantry group:
MD30460 $MA_BASE_FUNCTION_MASK, Bit 4 (control executing components)
MD30460 $MA_BASE_FUNCTION_MASK, Bit 5 (assignment to components)
Axial NC/PLC interface signals

Within the scope of the axis interchange function, the following axial NC/PLC interface
signals always have the same values for all axes of a closed gantry grouping:
DB31, ... DBX63.0 (reset executed)
DB31, ... DBX63.1 (PLC controlled axis)
DB31, ... DBX63.2 (axis stop active)
Axial system variable

Within the scope of the axis interchange function, the following axial system variables always
have the same values for all axes of a closed gantry group:
$AA_AXCHANGE_TYP (axis type regarding axis interchange)
$AA_AXCHANGE_STAT (axis status regarding axis interchange)
$AA_SNGLAX_STAT (axis type of the individual axis)
Mode group
Up to 10 mode groups are available for SINUMERIK 840D sl.
Only 1 mode group is available for SINUMERIK 828D.
Extended Functions
Channels
Up to 10 channels are available for SINUMERIK 840D sl.
Only 1 channel is available for SINUMERIK 828D.
Axis/spindle interchange
For SINUMERIK 828D, an axis/spindle interchange is not possible between channels.
Change to the channel axis

If an axis is changed from PLC axis, neutral axis or axis in another channel to the axis type
channel axis, a synchronization must take place.
With this synchronization,
the current positions are assumed
the current speed and gear stage is assumed with spindles.
It is therefore obligatory to perform a feed stop which interrupts the active path movement.
If the axis is transferred with GET, this transition is clearly defined by the parts program.
If the axis is allocated by the PLC, the program section in which the change takes place is
not clearly foreseeable.
(Except by a separate user-specific NC <-> PLC logic)
For this reason, the change to the channel axis is delayed in the following conditions:
Path operation is active (G64+ axes programmed)
Thread cutting/tapping is active (G33/G331/G332)
Change from a channel axis

The change of a channel axis to a neutral axis or PLC axes cannot be performed during an
active path operation.
With RELEASE this is caused by the fact that RELEASE must be located in a separate NC
block.
If the PLC changes the axis type, a REORG is triggered internally. Therefore, the change
with the listed program conditions is delayed.
Block search
During block search with calculation, all GET, GETD or RELEASE blocks are stored and
output after the next NC Start.
Exception:
Blocks which are mutually exclusive are deleted.
Example:
N10 RELEASE (AX1) Blocks are deleted.

N40 GET (AX1) "
N70 Target
Extended Functions
5.6 Data lists
5.6 Data lists
5.6.1 Machine data

10010 ASSIGN_CHAN_TO_MODE_GROUP[n] Channel valid in mode group [Channel No.]: 0, 1
10722 AXCHANGE_MASK Parameterization of the axis replacement response
Basic machine data of channel

20000 CHAN_NAME Channel name
20050 AXCONF_GEOAX_ASSIGN_TAB[n] Assignment of geometry axis to channel axis
[GEOAxisNo.]: 0...2
20060 AXCONF_GEOAX_NAME_TAB[n] Geometry axis name in channel
[GEOAxisNo.]: 0...2
20070 AXCONF_MACHAX_USED[n] Machine axis number valid in channel
[Channel axis No. ]: 0...7
20080 AXCONF_CHANAX_NAME_TAB[n] Name of channel axis in the channel
[Channel axis No.]: 0...7
20090 SPIND_DEF_MASTER_SPIND Initial setting of master spindle in channel
20100 DIAMETER_AX_DEF Geometry axis with transverse axis function
20110 RESET_MODE_MASK Determination of basic control settings after Reset/TP
End
20112 START_MODE_MASK Determination of basic control settings after NC start
20150 GCODE_RESET_VALUES[n] Reset G groups
[G-Group No.]: 0...59
20160 CUBIC_SPLINE_BLOCKS Number of blocks for C spline
20170 COMPRESS_BLOCK_PATH_LIMIT Maximum traversing length of NC block for
compression
20200 CHFRND_MAXNUM_DUMMY_BLOCKS Empty blocks with phase/radii
20210 CUTCOM_CORNER_LIMIT Max. angle for intersection calculation with tool radius
compensation
20220 CUTCOM_MAX_DISC Maximum value with DISC
Extended Functions
5.6 Data lists

20230 CUTCOM_CURVE_INSERT_LIMIT Maximum angle for intersection calculation with tool
radius compensation
20240 CUTCOM_MAXNUM_CHECK_BLOCKS Blocks for predictive contour calculation with tool
radius compensation
20250 CUTCOM_MAXNUM_DUMMY_BLOCKS Max. no. of dummy blocks with no traversing
movements with TRC
20270 CUTTING_EDGE_DEFAULT Basic setting of tool cutting edge without programming
20400 LOOKAH_USE_VELO_NEXT_BLOCK Look Ahead to programmed following block velocity
20430 LOOKAH_NUM_OVR_POINTS Number of override switch points for Look Ahead
20440 LOOKAH_OVR_POINTS[n] Override switch points for LookAhead
[Switch point No.]: 0...1
20500 CONST_VELO_MIN_TIME Minimum time with constant velocity
20600 MAX_PATH_JERK Pathrelated maximum jerk
20610 ADD_MOVE_ACCEL_RESERVE Acceleration reserve for overlaid movements
20650 THREAD_START_IS_HARD Acceleration behavior of axis with thread cutting
20700 REFP_NC_START_LOCK NC start disable without reference point
20750 ALLOW_GO_IN_G96 G0 logic in G96
20800 SPF_END_TO_VDI Subprogram end to PLC
21000 CIRCLE_ERROR_CONST Circle end point monitoring constant
21010 CIRCLE_ERROR_FACTOR Circle end point monitoring factor
21100 ORIENTATION_IS_EULER Angle definition for orientation programming
21110 X_AXIS_IN_OLD_X_Z_PLANE Coordinate system for automatic Frame definition
21200 LIFTFAST_DIST Traversing path for fast retraction from the contour
21250 START_INDEX_R_PARAM Number of first channelspecific R parameter
Auxiliary function settings of the channel

22000 AUXFU_ASSIGN_GROUP[n] Auxiliary function group
[aux. func. no. in channel]: 0...49
22010 AUXFU_ASSIGN_TYPE[n] Auxiliary function type
22020 AUXFU_ASSIGN_EXTENSION[n] Auxiliary function extension
22030 AUXFU_ASSIGN_VALUE[n] Auxiliary function value
22200 AUXFU_M_SYNC_TYPE Output timing of M functions
22210 AUXFU_S_SYNC_TYPE Output timing of S functions
22220 AUXFU_T_SYNC_TYPE Output timing of T functions
22230 AUXFU_H_SYNC_TYPE Output timing of H functions
Extended Functions
5.6 Data lists

22240 AUXFU_F_SYNC_TYPE Output timing of F functions
22250 AUXFU_D_SYNC_TYPE Output timing of D functions
22260 AUXFU_E_SYNC_TYPE (available soon) Output timing of E functions
22400 S_VALUES_ACTIVE_AFTER_RESET S function active after RESET
22410 F_VALUES_ACTIVE_AFTER_RESET F function active after reset
22500 GCODE_OUTPUT_TO_PLC G functions to PLC
22550 TOOL_CHANGE_MODE New tool offset for M function
22560 TOOL_CHANGE_M_CODE M function for tool change
Channel-specific memory settings

25000 REORG_LOG_LIMIT Percentage of IPO buffer for log file enable
28000 MM_REORG_LOG_FILE_MEM Memory size for REORG (DRAM)
28010 MM_NUM_REORG_LUD_MODULES Number of blocks for local user variables for REORG (DRAM)
28020 MM_NUM_LUD_NAMES_TOTAL Number of local user variables (DRAM)
28030 MM_NUM_LUD_NAMES_PER_PROG Number of local user variables per program (DRAM)
28040 MM_LUD_VALUES_MEM Memory size for local user variables (DRAM)
28050 MM_NUM_R_PARAM Number of channelspecific R parameters (SRAM)
28060 MM_IPO_BUFFER_SIZE Number of NC blocks in IPO buffer (DRAM)
28070 MM_NUM_BLOCKS_IN_PREP Number of blocks for block preparation (DRAM)
28080 MM_NUM_USER_FRAMES Number of settable Frames (SRAM)
28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for compile cycles (DRAM)
28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for compile cycles (DRAM)
28500 MM_PREP_TASK_STACK_SIZE Stack size of preparation task (DRAM)
28510 MM_IPO_TASK_STACK_SIZE Stack size of IPO task (DRAM)

30460 BASE_FUNCTION_MASK Axis functions
30550 AXCONF_ASSIGN_MASTER_CHAN Reset position of channel for axis change
30552 AUTO_GET_TYPE Definition of automatic GET
30600 FIX_POINT_POS Fixed value positions of axes with G75
32074 FRAME_OR_CORRPOS_NOTALLOWED Frame or HL offset are not allowed
33100 COMPRESS_POS_TOL Maximum deviation with compensation
Extended Functions
5.6 Data lists
5.6.2 Setting data
5.6.2.1 Channelspecific setting data
Number Identifier: $SC_ Description

42000 THREAD_START_ANGLE Start angle for thread
42100 DRY_RUN_FEED Dry run feedrate
5.6.3 Signals
5.6.3.1 Signals to/from BAG

The mode group signals from the PLC to the NCK and from the NCK to the PLC are included
in data block 11.
The signals are described in:
Reference:
Function Manual, Basic Functions; NC/PLC Interface Signals (Z1),
Chapter "Mode group, Program Operation (K1)"
5.6.3.2 Signals to/from Channel

The channel signals from the PLC to the NCK and from the NCK to the PLC are included in
data blocks 21, 22, ... for the first, second ... channel.
The signals are described in:
Reference:
Function Manual, Basic Functions; NC/PLC Interface Signals (Z1),
Chapter "Mode group, Program Operation (K1)"
Extended Functions
M1: Kinematic transformation 6
6.1.1 TRANSMIT (option)
Note
The "TRANSMIT and peripheral surface transformation" option that is under license is
required for the "TRANSMIT" function.
The "TRANSMIT" function permits the following services:

Face-end machining on turned parts in the turning clamp
Holes
Contours
A cartesian coordinate system can be used to program these machining operations.
The control maps the programmed traversing movements of the Cartesian coordinate
system onto the traversing movements of the real machine axes (standard situation):
Rotary axis (1)
Infeed axis vertical to the axis of rotation (2)
Longitudinal axis parallel to the axis of rotation (3)
Linear axes (2) and (3) are perpendicular to one another.
A tool center offset relative to the turning center is permitted.
The velocity control makes allowance for the limits defined for rotary motion.
A path in the cartesian coordinate system must not pass through the turning center point
(this restriction applies to SW 2 and 3).
Other system variables
The tool center point path can pass through the turning center point of the rotary axis.
The rotary axis does not need to be a modulo axis.
Extended Functions
M1: Kinematic transformation
6.1.2 TRACYL (option)
Note
The "TRANSMIT and peripheral surface transformation" option that is under license is
required for the function "Cylinder surface transformation (TRACYL)".
The function "Cylinder surface transformation (TRACYL)" permits the following services:
Machining of
Longitudinal grooves on cylindrical bodies,
Transverse grooves on cylindrical bodies
Arbitrary groove patterns on cylindrical objects.
The path of the grooves is programmed with reference to the unwrapped, level surface of the
cylinder.
For machining, lathes with
X-C-Z kinematics and
X-Y-Z-C kinematics
are supported..
The control transforms the programmed traversing movements of the cylinder coordinate
system into the traversing movements of the real machine axes (standard applications X-
C-Z kinematics TRAFO_TYPE_n = 512):
Rotary axis (1)
Note
Linear axes (2) and (3) are perpendicular to one another. The infeed axis (2)
intersects the rotary axis. This constellation does not permit groove side offset.
For groove side offset, X-Y-Z-C kinematics is required with the following axes
(TRAFO_TYPE_n = 513):
Rotary axis (1)
Longitudinal axis (4) to supplement (2) and (3) to obtain a right-hand cartesian
coordinate system.
Note
Linear axes (2), (3) and (4) are perpendicular to one another. This constellation
permits groove wall corrections.
Extended Functions
The velocity control makes allowance for the limits defined for rotary motion.
TRACYLtransformation, without groove side compensation, with additional longitudinal axis
(cylinder surface curve transformation without groove side offset TRAFO_TYPE_n= 514)
Transformation without groove side offset requires only a rotary axis and a linear axis
positioned perpendicular to the rotary axis.
If a machine provides an additional linear axis positioned perpendicular to the rotary axis
and first linear axis, this can be utilized to improve tool offset.
6.1.3 TRAANG (option)
Note
The "Inclined axis" option under license is required for the function "Inclined axis
(TRAANG)".
The function "Inclined axis (TRAANG)" is intended for grinding applications. It allows the
following:
Machining with inclined infeed axis.
A cartesian coordinate system can be used for programming purposes.
The control maps the programmed traversing movements of the Cartesian coordinate
system onto the traversing movements of the real machine axes (standard situation):
Inclined infeed axis.
6.1.4 Chained transformations
Introduction
Two transformations can be chained so that the motion components for the axes from the
first transformation are used as input data for the chained second transformation. The motion
parts from the second transformation act on the machine axes.
Chaining options
The chain may include two transformations.
The second transformation must be "Inclined axis" (TRAANG).
The first transformation can be:
Orientation transformations (TRAORI), incl. universal milling head
TRANSMIT
TRACYL
TRAANG
For more information about the other transformations, please refer to:
References:
Function Manual, Special Function; 3- to 5-axis Transformations (F2).
Extended Functions
6.2 TRANSMIT face end transformation (option)
6.1.5 Activating transformation machine data via parts program/softkey

Most of the machine data relevant to kinematic transformations were activated by POWER
ON up to now.
Transformation machine data can also be activated via the parts program/softkey and it is
not necessary to boot the control.

Key statement
The TRANSMIT transformation permits the face end machining on turning machines.
&0
<
;0
==0
X Geometry axis
Y Geometry axis
Z Geometry axis
XM Machine axis
ZM Machine axis
CM Machine axis
Note
For active transformation, the names of the involved machine, channel and geometry axes
are different:
MD10000 $MN_AXCONF_MACHAX_NAME_TAB (machine axis name)
MD20080 $MC_AXCONF_CHANAX_NAME_TAB (channel axis name)
MD20060 $MC_AXCONF_GEOAX_NAME_TAB (geometry axis name)
Extended Functions
Machine data
General transformation data

$MC_TRAFO_GEOAX_ASSIGN_TAB_<n>
$MC_TRAFO_TYPE_<n>
$MC_TRAFO_AXES_IN_<n>
with n = 1, 2, 3, ... max. number of transformation data records
Note
Maximum of two TRANSMIT transformations per channel
A maximum of two TRANSMIT transformations may be parameterized per channel.
$MC_TRAFO_TYPE_<n> = 256 or 257
TRANSMIT-specific machine data

$MC_TRANSMIT_ROT_AX_OFFSET_<t>
$MC_TRANSMIT_ROT_SIGN_IS_PLUS_<t>
$MC_TRANSMIT_BASE_TOOL_<t>
$MC_TRANSMIT_POLE_SIDE_FIX_<t>
with t = 1, 2
6.2.1 Specific settings
One rotary and one linear axis: TRAFO_TYPE = 256

The transformation type 256 must be set for TRANSMIT with a rotary and a linear axis:
$MC_TRAFO_TYPE_<n> = 256
with n = 1, 2, ... max. number of transformations
Transformation input axes: $MC_TRAFO_AXES_IN_<n>

Those channel axes are specified in the machine data on which the axes of the
transformation Cartesian coordinate system are to be mapped:
$MC_TRAFO_AXES_IN_<n>[ <index> ] = <channel axis number>
<Index> Meaning
0 Linear axis perpendicular to rotary axis
1 Rotary axis
2 Linear axis parallel to rotary axis
The channel axis numbers must refer to the axis sequence defined with
$MC_TRAFO_GEOAX_ASSIGN_TAB_<n>.
Extended Functions
One rotary and two linear axes: TRAFO_TYPE = 257

The transformation type 257 must be set for TRANSMIT with a rotary and two linear axes:
$MC_TRAFO_TYPE_<n> = 257
The second linear axis must be oriented perpendicular to the plane clamped by the rotary
and the linear axis. The second linear axis for TRANSMIT is used exclusively for tool
correction.
Transformation input axes: $MC_TRAFO_AXES_IN_<n>

Those channel axes are specified in the machine data on which the axes of the
transformation Cartesian coordinate system are to be mapped:
$MC_TRAFO_AXES_IN_<n>[ <index> ] = <channel axis number>
<Index> Meaning
0 Linear axis perpendicular to rotary axis
1 Rotary axis
2 Linear axis parallel to rotary axis
3 Linear axis perpendicular to the axes from index 0 and 1
The channel axis numbers must refer to the axis sequence defined with
$MC_TRAFO_GEOAX_ASSIGN_TAB_<n>.
Rotary axis offset: TRANSMIT_ROT_AX_OFFSET

If the rotary axis zero point does not match the rotary axis zero position when the
TRANSMIT transformation is active, the angular difference must be entered as an offset in
the machine data:
$MC_TRANSMIT_ROT_AX_OFFSET_<t> = <angular difference>
with t = 1, 2
Extended Functions
Direction of rotation: TRANSMIT_ROT_SIGN_IS_PLUS

TRANSMIT must be informed of the rotary axis direction of rotation with the following
machine data:
The rotary axis direction of rotation with regard to TRANSMIT is positive if the rotary axis
rotates counterclockwise in relation to the X/Y plane looking at the X axis, when
traversing in the positive direction.
The rotary axis direction of rotation with regard to TRANSMIT is negative if it rotates
clockwise when traversing in the positive direction

< <
; ;
= =
Positive direction of rotation

Negative direction of rotation
Figure 6-1 Rotary axis direction of rotation
$MC_TRANSMIT_ROT_SIGN_IS_PLUS_<t> = <direction of rotation>

with t = 1, 2
<Direction of rotation> Meaning

0 Negative rotary axis direction of rotation internal sign reversal
1 Positive rotary axis direction of rotation no internal sign reversal
Position of tool zero: TRANSMIT_BASE_TOOL

The position of the tool zero is specified in relation to the origin of the effective Cartesian
coordinate system for TRANSMIT:
MD24920 $MC_TRANSMIT_BASE_TOOL_<t>[ 0 ] = <offset in X>
MD24920 $MC_TRANSMIT_BASE_TOOL_<t>[ 1 ] = <offset in Y>
MD24920 $MC_TRANSMIT_BASE_TOOL_<t>[ 2 ] = <offset in Z>
with t = 1, 2
Extended Functions
Replaceable geometry axes

When the GEOAX() geometry axes are switched, the parameterized M function is output to the
NC/PLC interface:
MD22534 $MC_TRAFO_CHANGE_M_CODE = <M function>
Note
The values 0 to 6, 17 and 30 are not output.
References:
Function Manual Basic Functions; K2, "Coordinate Systems, Axis Types, Axis
Configurations, Workpiece-related Actual-Value System, External Zero Offset"
6.2.2 Switch on
The TRANSMIT transformation is activated in the part program or synchronous action using
the TRANSMIT command.
Syntax
TRANSMIT
TRANSMIT(n)
TRAFOOF
Meaning
TRANSMIT: Activate TRANSMIT with the first TRANSMIT data set

TRANSMIT(n): Activate TRANSMIT with the nth TRANSMIT data set
6.2.3 Deactivation
A TRANSMIT transformation active in the channel is activated with:
Deactivate transformation: TRAFOOF
Activate another transformation, e.g. TRACYL, TRAANG, TRAORI
Extended Functions
6.2.4 Applications
Introduction
The transformation TRANSMIT has a pole at the zero point of the TRANSMIT plane (example, see
figure: 21, x = 0, Y = 0). The pole is located on the intersection between the radial linear
axis and the rotary axis (X and CM). In the vicinity of the pole, small positional changes in
the geometry axes generally result in large changes in position in the machine rotary axis.
The only exceptions are linear motions into or through the pole.
A tool center point path through the pole does not cause the parts program to be aborted.
There are no restrictions with respect to programmable traversing commands or active tool
radius compensations. Nevertheless, workpiece machining operations close to the pole are
not recommended since these may require sharp feedrate reductions to prevent overloading
of the rotary axis.
New features
Definition:
A pole is said to exist if the line described by the tool center point intersects the turning
center of the rotary axis.
The following cases are covered:
Under what conditions and by what methods the pole can be traversed
The response in pole vicinity
The response with respect to working area limitations
Monitoring of rotary axis rotations over 360.
Pole traversal
The pole can be traversed by two methods:
Traversal along linear axis
Traversal into pole with rotation of rotary axis in pole
Extended Functions
Traversal along linear axis
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Figure 6-2 Traversal of x axis through pole
Rotation in pole
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Figure 6-3 Traversal of x axis into pole (a), rotation (b), exit from pole (c)
Selection of method
The method must be selected according to the capabilities of the machine and the
requirements of the part to be machined. The method is selected by machine data:
MD24911 $MC_TRANSMIT_POLE_SIDE_FIX_1
Extended Functions
The first MD applies to the first TRANSMIT transformation in the channel and the second MD
correspondingly to the second TRANSMIT transformation.
VALUE Meaning
0 Pole traversal
The tool center point path (linear axis) must traverse the pole on a
continuous path.
1 Rotation around the pole.
The tool center point path must be restricted to a positive traversing range
of the linear axis (in front of turning center).
2 Rotation around the pole.
The tool center point path must be restricted to a negative traversing
range of the linear axis (behind turning center).
Special features relating to pole traversal

The method of pole traversal along the linear axis may be applied in the AUTOMATIC and
JOG modes.
System response:
Table 6- 1 Traversal of pole along the linear axis
Operating mode State Response

AUTOMATIC All axes involved in the High-speed pole traversal
transformation are moved
synchronously. TRANSMIT active.
Not all axes involved in the Traversal of pole at creep speed
transformation are traversed
synchronously (e.g. position axis).
TRANSMIT not active
An applied DRF (external zero Abortion of machining, alarm
offset) does not interfere with the
operation. Servo errors may occur
close to the pole during application
of a DRF.
JOG - Traversal of pole at creep speed
Special features relating to rotation in pole

Precondition: This method is only effective in the AUTOMATIC mode.
MD24911 $MC_TRANSMIT_POLE_SIDE_FIX_1 = 1 or 2
Value: 1 Linear axis remains within positive traversing range
Value: 2 Linear axis remains within negative traversing range
Extended Functions
In the case of a contour that would require the pole to be traversed along the tool center
point path, the following three steps are taken to prevent the linear axis from traversing in
ranges beyond the turning center:
Step Action
1 Linear axis traverses into pole
2 Rotary axis turns through 180, the other axes involved in the transformation
remain stationary.
3 Execution of remaining block. The linear axis now exits from the pole again.
In JOG mode, the motion stops in the pole. In this mode, the axis may exit from the pole only
along the path tangent on which it approached the pole. All other motion instructions would
require a step change in the rotary axis position or a large machine motion in the cases of
minimum motion instructions. They are rejected with alarm 21619.
Traversal close to pole

If a tool center point traverses past the pole, the control system automatically reduces the
feedrate and path acceleration rate such that the settings of the machine axes (MD 32000
$MA_MAX_AX_VELO[AX*] and MD32300 $MA_ MAX_AX_ACCEL[AX*]) are not exceeded.
The closer the path is to the pole, the greater the reduction in the feedrate.
Tool center point path with corner in pole

A tool center point path which includes a corner in the pole will not only cause a step change
in axis velocities, but also a step change in the rotary axis position. These cannot be reduced
by decelerating.
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Figure 6-4 Pole traversal
Extended Functions
Requirements:
AUTOMATIC mode,
MD24911 $MC_TRANSMIT_POLE_SIDE_FIX_1 = 0
or
The control system inserts a traversing block at the step change point. This block generates
the smallest possible rotation to allow machining of the contour to continue.
Corner without pole traversal
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Figure 6-5 Machining on one pole side
Requirements:
AUTOMATIC mode,
or
The control system inserts a traversing block at the step change point. This block generates
the necessary rotation so that machining of the contour can continue on the same side of the
pole.
Extended Functions
Transformation selection in pole

If the machining operation must continue from a position on the tool center path which
corresponds to the pole of the activated transformation, then an exit from the pole is
specified for the new transformation.
If
or
is set (pole transition), then a rotation as small as possible is generated at the beginning of
the block originating in the pole. Depending on this rotation, the axis then traverses either in
front of or behind the turning center.
For
or
machining is done before the rotational center point (linear axis in positive traversing range),
for
or
behind the rotational center point (linear axis in negative traversing range).
Transformation selection outside pole

The control system moves the axes involved in the transformation without evaluating
machine data MD24911 $MC_TRANSMIT_POLE_SIDE_FIX_t. In this case, t = 1 stands for
the first and t = 2 for the second TRANSMIT transformation in the channel.
Extended Functions
6.2.5 Working area limitations
Starting position
When TRANSMIT is active, the pole is replaced by a working area limitation if the tool center
point cannot be positioned in the turning center of the rotary axis involved in the
transformation. This is the case when the axis perpendicular to the rotary axis (allowing for
tool offset) is not positioned on the same radial plane as the rotary axis or if both axes are
positioned mutually at an oblique angle. The distance between the two axes defines a
cylindrical space in the BCS in which the tool cannot be positioned.
The illegal range cannot be protected by the software limit switch monitoring function since
the traversing range of the machine axes is not affected.
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Figure 6-6 Working area limitation based on offset linear axis
Traverse into working area limitation

Any motion that leads into the working area limitation is rejected with alarm 21619. Any
corresponding parts program block is not processed. The control system stops processing at
the end of the preceding block.
If the motion cannot be foreseen promptly enough (JOG modes, positioning axes), then the
control stops at the edge of the working area limitation.
Response close to working area limitation

If a tool center point traverses past the prohibited range, the control system automatically
reduces the feedrate and path acceleration rate such that the settings of the machine axes
(MD 32000 $MA_MAX_AX_VELO[AX*] and MD32300 $MA_ MAX_AX_ACCEL[AX*]) are not
exceeded. The closer the path is to the working area limitation, the greater the reduction in
the feedrate may be.
Extended Functions
6.2.6 Overlaid motions with TRANSMIT

The control system cannot predict overlaid motions. However, these do not interfere with the
function provided that they are very small (e.g. fine tool offset) in relation to the current
distance from the pole (or from working area limitation). With respect to axes that are
relevant for the transformation, the transformation monitors the overlaid motion and signals
any critical quantity by alarm 21618. This alarm indicates that the block-related velocity
planning function no longer adequately corresponds to the actual conditions on the machine.
When the alarm is output, the conventional, non-optimized online velocity monitor is
therefore activated. The preprocessing routine is re-synchronized with the main run by a
REORG generated internally in the control.
Alarm 21618 should be avoided whenever possible since it indicates a state that can lead to
axis overload and thus abortion of parts program processing.
6.2.7 Monitoring of rotary axis rotations over 360
Ambiguity of rotary axis positions

The positions of the rotary axis are ambiguous with respect to the number of rotations. The
control breaks down blocks containing several rotations around the pole into sub-blocks.
This subdivision must be noted with respect to parallel actions (e.g. output of auxiliary
functions, block-synchronized positioning axis motions) since the programmed block end is
no longer relevant for synchronization, but the end of the first sub-block.
Reference:
Function Manual Basic Functions; "H2: Auxiliary function outputs to the PLC"
Function Manual Synchronized Actions
In single block operation the control system machines individual blocks explicitly. Otherwise
the sub-blocks are traversed with Look Ahead just like a single block. A limitation of the
rotary axis setting range is monitored by the software limit switch monitoring function.
6.2.8 Constraints
Look Ahead
All functions requiring Look Ahead (traversal through pole, Look Ahead) work satisfactorily
only if the relevant axis motions can be calculated exactly in advance. With TRANSMIT, this
applies to the rotary axis and the linear axis perpendicular to it. If one of these axes is the
positioning axis, then the Look Ahead function is deactivated by alarm 10912 and the
conventional online velocity check activated instead.
Selection of method
The user is responsible for making the optimum choice of "Traversal through pole" or
"Rotation around pole".
Extended Functions
Several pole traversals

A block can traverse the pole any number of times (e.g. programming of a helix with several
turns). The part program block is subdivided into a corresponding number of sub-blocks.
Analogously, blocks which rotate several times around the pole are likewise divided into sub-
blocks.
Rotary axis as modulo axis

The rotary axis can be a modulo rotary axis. However, this is not a mandatory requirement
as was the case in SW 2 and 3. The relevant restrictions applying in SW 2 and 3 have been
eliminated.
Rotary axis as spindle

If the rotary axis without transformation is used as a spindle, it must be switched to position-
controlled mode with SPOS before the transformation is selected.
TRANSMIT with supplementary linear axis

With active TRANSMIT, the channel name of posBCS[ax[3]] must have another name in the
part program, like the geometry axes. If posBCS[ax[3]] is written only outside the TRANSMIT
transformation, this restriction does not apply if the axis has been assigned to a geometry
axis. With active TRANSMIT, no contour information is processed via ax[3].
REPOS
It is possible to reposition on the sub-blocks produced as a result of the extended TRANSMIT
function in SW 4. In this case, the control uses the first sub-block that is closest to the
repositioning point in the BCS.
Block search
In the case of block search with calculation, the block end point (of the last sub-block) is
approached in cases where intermediate blocks have been generated as the result of the
extended functionality in SW 4.
6.2.9 Example: Axis configuration

Example of a TRANSMIT axis configuration with two linear axes and one rotary axis.
Channel axes
Geometry axis names

MD20060 $MC_AXCONF_GEOAX_NAME_TAB[0]="X"
MD20060 $MC_AXCONF_GEOAX_NAME_TAB[1]="Y"
MD20060 $MC_AXCONF_GEOAX_NAME_TAB[2]="Z"
Extended Functions
Assignment of geometry axes to channel axes

TRANSMIT not active
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[ 0 ] = 1 (1st geometry axis 1st
channel axis "XC")
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[ 1 ] = 0 ( - )
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[ 2 ] = 2 (3rd geometry axis 2nd
channel axis "ZC")
TRANSMIT active
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[ 0 ] = 1 (1st geometry axis 1st
channel axis "XC")
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[ 1 ] = 3 (2nd geometry axis 3rd
channel axis "CC")
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[ 2 ] = 2 (3rd geometry axis 2nd
channel axis "ZC")
Channel axis names

MD20080 $MC_AXCONF_CHANAX_NAME_TAB[0]="XC"
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[1]="ZC"
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[2]="CC"
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[3]="ASC"
Assignment of channel axes to machine axes

MD20070 $MC_AXCONF_MACHAX_USED[ 0 ] = 2 (2nd machine axis "XM")
MD20070 $MC_AXCONF_MACHAX_USED[ 1 ] = 3 (3rd machine axis "ZM")
MD20070 $MC_AXCONF_MACHAX_USED[ 2 ] = 1 (1st machine axis / spindle "CM")
MD20070 $MC_AXCONF_MACHAX_USED[ 3 ] = 4 (4th machine axis / spindle "ASM")
Machine axes
Spindles
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ 0 ] = 1 (1st machine axis 1st spindle)
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ 1 ] = 0 (2nd machine axis axis)
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ 2 ] = 0 (3rd machine axis axis)
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ 3 ] = 2 (4th machine axis 2nd spindle)
Extended Functions
Machine axis name

MD10000 $MN_AXCONF_MACHAX_NAME_TAB[0]="CM"
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[1]="XM"
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[2]="ZM"
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[3]="ASM"
Synopsis of the axis configuration
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Extended Functions
6.3 TRACYL cylinder surface transformation (option)

The TRACYL transformation permits the machining of cylinder jacket curves (grooves) on
turning machines. The machine kinematics must correspond to the cylinder coordinate
system:
One, two or three linear axes and one rotary axis
The linear axes must be oriented perpendicular to each other
The rotary axis must be oriented parallel to one of the linear axes
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Figure 6-7 TRACYL cylinder surface transformation
Note
are different:
Extended Functions
One or two linear axes (axis configuration 1)
One linear axis

For a machine kinematic with only one linear axis (X), only grooves parallel to the periphery
of the cylinder can be generated.
Two linear axes

For a machine kinematic with two linear axes (X and Z), grooves of any form can be
generated on the cylinder.
The angularity of the groove edges for groove widths larger than the tool diameter:
Grooves parallel to the circumference groove edges parallel to each other
Grooves parallel to the rotary axis groove edges at angle to each other
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XM Infeed axis perpendicular to the turning center

ZM Linear axis parallel to the turning center
Y / CM Transformatory Y axis / rotary axis
ASM Working spindle
Figure 6-8 Without groove side correction
Extended Functions
Three linear axes (axis configuration 2)

For a machine kinematic with three linear axes (X, Y and Z), grooves of any form can be
generated on the cylinder.
The Y axis oriented perpendicular to the turning center means almost parallel groove edges
can be generated even for groove widths larger than the tool diameter.
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XM Infeed axis perpendicular to the turning center

YM Supplementary axis perpendicular to the X-Z plane
ZM Linear axis parallel to the turning center
Y / CM Transformatory Y axis / rotary axis
ASM Working spindle
Figure 6-9 With groove side correction
6.3.1 Preconditions
Maximum number of TRACYL transformations per channel

The following machine data can be used to define transformation data records in a channel:
$MC_TRAFO_TYPE_<n>
Maximum two data records can be used for the TRACYL, $MC_TRAFO_TYPE_<n> = 512, 513
or 514 transformation in a channel.
Extended Functions
Machine data for TRACYL transformation

A TRACYL transformation is parameterized using the following machine data:
$MC_TRACYL_ROT_AX_OFFSET_<t> (offset of rotary axis)
$MC_TRACYL_ROT_AX_FRAME_<t> (rotary axis offset)
$MC_TRACYL_DEFAULT_MODE_<t> (selection of TRACYL mode)
$MC_TRACYL_ROT_SIGN_IS_PLUS_<t> (sign of the rotary axis)
$MC_TRACYL_BASE_TOOL_<t> (vector of the base tool)
with n = 1, 2, ... max. number of possible TRACYL transformations
Sample axis configuration
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Figure 6-10 Axis configuration for the example in Figure "Machining grooves on a cylinder surface
with X-Y-Z-C kinematics"
The configurations highlighted in the figure above apply when TRACYL is active.
Extended Functions
Geometry axis names

MD20050 $MC_AXCONF_GEOAX_NAME_TAB[0]="X"
MD20050 $MC_AXCONF_GEOAX_NAME_TAB[1]="Y"
MD20050 $MC_AXCONF_GEOAX_NAME_TAB[2]="Z"
TRACYL not active

MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[ 0 ] = 1
TRACYL active
$MC_TRAFO_GEOAX_ASSIGN_TAB_<n>[ 0 ] = 1
Channel axis names

MD20080 $MC_AXCONF_CHANAX_NAME_TAB[1]="YC"
Assignment of channel axes to machine axes

MD20070 $MC_AXCONF_MACHAX_USED[ 0 ] = 2
Identification of spindles
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ 0 ] = 1 (spindle)
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ 1 ] = 0 (axis)
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[ 4 ] = 2 (spindle)
Extended Functions
Machine axis name

MD10000 $MN_AXCONF_MACHAX_NAME_TAB[0]="CM"
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[1]="XM"
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[2]="YM"
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[3]="ZM"
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[4]="ASM"
See also
TRACYL cylinder surface transformation (option) (Page 366)
Setting of the transformation type

The transformation type is set transformation-data-record-specific via:
$MC_TRAFO_TYPE_<n> = <transformation type>
The user must specify the transformation type for the transformation data blocks. For TRACYL
a VALUE of 512 must be set for axis configuration 1 and a value of 513 for axis configuration
2 or 514 for transformation with additional linear axis.
The transformation with additional linear axis can be activated with and without groove side
offset (see Section "Switch on (Page 375)").
Transformation type 514 without groove side offset

Cylinder surface curve transformation TRAFO_TYPE_n = 514
If the machine has another linear axis which is perpendicular to both the rotary axis and the
first linear axis, transformation type 514 can be used to apply tool offsets with the real Y axis.
In this case, it is assumed that the working area of the second linear axis is small and will not
be used to execute the part program.
The existing settings for MD10000 $MC_TRAFO_GEOAX_ASSIGN_TAB_n apply.
Grooves with groove side offset

The required inclusion of the tool offset has already been taken into account for the TRACYL
transformation with groove side offset.
Axis image
The following paragraph describes how the transformation axis image is specified.
Extended Functions
Transformation geometry axes

Three (or four) channel axis numbers must be specified for TRACYL :
MD24110 $MC_TRAFO_AXES_IN_1[0]=channel axis number of the axis radial to the
rotary axis.
MD24110 $MC_TRAFO_AXES_IN_1[1]=channel axis number of the rotary axis.
MD24110 $MC_TRAFO_AXES_IN_1[2]=channel axis number of the axis parallel to the
rotary axis.
MD24110 $MC_TRAFO_AXES_IN_1[3]=channel axis number of the supplementary axis
parallel to the cylinder surface and perpendicular to the rotary axis (provided two axis
configurations are present).
The axis numbers must refer to the channel axis sequences defined by the following
machine data:
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_n
Grooves without groove wall offset

For transformation type 514 the following indices apply to MD24110
$MC_TRAFO_AXES_IN_n[ ].
Meaning of indices in relation to base coordinate system (BCS):
[0]: Cartesian axis radial to rotary axis (if configured)
[1]: Axis in generated cylinder surface perpendicular to rotary axis
[2]: Cartesian axis parallel to rotary axis
[3]: Linear axis parallel to index 2 in initial position of machine
Meaning of indices in relation to machine coordinate system (MCS):
[0]: Linear axis radial to rotary axis (if configured)
[1]: Rotary axis
[2]: Linear axis parallel to rotary axis
[3]: Linear axis perpendicular to the axes of indices [0] and [1]
Extended Functions
Rotational position
The rotational position of the axis on the cylinder peripheral surface perpendicular to the
rotary axis must be defined as follows:
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Figure 6-11 Center of axis rotation in the peripheral cylinder surface
MD24800 TRACYL_ROT_AX_OFFSET_<t>
The rotational position of the peripheral surface in relation to the defined zero position of the
rotary axis is specified with:
MD24800 $MC_TRACYL_ROT_AX_OFFSET_t=...
In this case, "t" is substituted by the number of TRACYL transformations declared in the
transformation data blocks (t may not be greater than 2).
Direction of rotation
The direction of rotation of the rotary axis is specified by machine data as described in the
following paragraph.
TRACYL_ROT_SIGN_IS_PLUS_<t>
If the direction of rotation of the rotary axis on the x-y plane is counterclockwise when viewed
against the z axis, then the machine data must be set to TRUE, otherwise to FALSE.
758(

[
MD24810 $MC_TRACYL_ROT_SIGN_IS_PLUS_t=TRUE
In this case, "t" is substituted by the number of TRACYL transformations declared in the
transformation data blocks (t may not be greater than 2).
Extended Functions
Replaceable geometry axes

The PLC is informed when a geometry axis has been replaced using GEOAX( ) through the
optional output of an M code that can be set in machine data.
MD22534 $MC_TRAFO_CHANGE_M_CODE
Number of the M code that is output at the VDI interface in the case of transformation
changeover.
Note
If this machine data is set to one of the values 0 to 6, 17, 30, then no M code is output.
References:
Function Manual Basic Functions; Coordinate Systems, Axis Types, Axis Configurations,
Workpiece-related Actual-Value System, External Zero Offset (K2)
Position of tool zero

The position of the tool zero point in relation to the origin of the Cartesian coordinate system
is specified by machine data as described in the following paragraph.
MD24820 TRACYL_BASE_TOOL_<t>
This machine data is used to inform the control of the tool zero point position in relation to
the origin of the cylinder coordinate system declared for TRACYL. The machine data has three
components for the axes X, Y, Z of the machine coordinate system.
W\
W[
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Figure 6-12 Position of tool zero in relation to machine zero
Extended Functions
Example
MD24820 $MC_TRACYL_BASE_TOOL_<t>[ 0 ] = tx
MD24820 $MC_TRACYL_BASE_TOOL_<t>[ 1 ] = ty
MD24820 $MC_TRACYL_BASE_TOOL_<t>[ 2 ] = tz
Where <t> = number of TRACYL transformations defined in the transformation data records

=
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Figure 6-13 Cylinder coordinate system
See also
TRACYL cylinder surface transformation (option) (Page 366)
6.3.3 Switch on
The TRACYL transformation is activated in the part program or synchronous action using the
TRACYL command.
Syntax
TRACYL(<d>[, <n>][, <k>])
Extended Functions
Meaning
TRACYL(<d>): Activate TRACYL with TRACYL data set 1 and working diameter d
TRACYL(<d>, <n>): Activate TRACYL with TRACYL data set n and working diameter d
<d>: Reference or working diameter.
Range of values: >1
<n>: TRACYL data set number (optional)
Range of values: 1, 2
<k>: The parameter is only relevant for transformation type 514 (optional).
k = 0: without groove side correction
k = 1: with groove side correction
If the parameter is not specified, then the parameterized basic position
applies: $MC_TRACYL_DEFAULT_MODE_<n>
6.3.4 Deactivation
A TRACYL transformation active in the channel is switched-off with:
Activate another transformation, e.g. TRAANG, TRANSMIT, TRAORI
6.3.5 Boundary conditions
Selection/deselection
An intermediate motion block is not inserted (phases/radii).
A series of spline blocks must be concluded.
Tool radius compensation must be deselected.
The frame which was active prior to TRACYL is deselected by the control system (analog
G500).
An active working area limit is deselected for axes affected by the transformation (analog
WALIMOF).
Continuous path control and rounding are interrupted.

DRF offsets must have been deleted by the operator.
The Y axis used for the compensation should be set to zero for selection and active
groove side compensation.
Tool change
Tools can be changed only when the tool radius compensation function is deselected.
Extended Functions
Frame
A frame change with G91 (incremental dimension) is not specially treated for active
transformation. The path to be traversed is evaluated in the workpiece coordinate system of
the new frame - regardless of which frame was active in the previous block.
A rotary axis offset can, for example, be entered by compensating the inclined position of a
workpiece can be considered using a frame or as offset of the rotary axis.
The following setting is required for the axial complete frame of the rotary axis to act in the
transformation:
$MC_TRACYL_ROT_AX_FRAME_<t> = 1
Note
Changes in the axis assignments are converted every time the transformation is selected or
deselected.
References:
Function Manual Basic Functions; "Co-ordinate Systems, Frames" (K2)
Function restriction for transformation axes

The axes involved on the cylinder surface transformation must not be used for the following
functions:
Positioning axis
Oscillating axis
Preset axis
Fixed point approach G75
Reference point approach G74
Manual traversal in JOG

When generated cylinder surface transformation with groove side compensation
($MC_TRAFO_TYPE = 513) is active in JOG mode, it must be noted that the axes are
traversed depending on the preceding status in AUTOMATIC. For active groove side
compensation, the axes so move differently than for deselected compensation. The part
program can therefore be continued (REPOS) after a part program interruption.
Extended Functions
6.4 TRAANG oblique angle transformation (option)
Interrupt part program

Mode change from AUTOMATIC to JOG
If a part program machining is interrupted for active transformation and traversed
manually in the JOG operating mode, ensure for continuation of the part program in the
AUTOMATIC operating mode that the transformation is already active in the restart block
from the current position to the interruption location.
WARNING
Risk of collision
No monitoring for collisions takes place.
The operator is responsible for ensuring that the tool can be re-positioned without any
difficulties.
START after RESET

If a part program machining is interrupted with RESET and restarted with START, ensure that
at part program begin all axes travel with a linear block (G0 or G1) to a defined position,
and the remaining part program is traversed reproducably. A tool which was active on
RESET may no longer be taken into account by the control (settable via machine data).

The angle transformation or "inclined axis" transformation permits the programming in the
perpendicular workpiece coordinate system (WCS) on machines with inclined machine axes.
A typical axis orientation for grinding machines:
08
*ULQGLQJGLVN
;
&
$6
=0=
:RUNSLHFH
X Geometry axis
Z Geometry axis
MZ Machine axis
MU Machine axis
Angle of inclined axis
Extended Functions
Note
are different:
6.4.1 Preconditions
Maximum number of TRAANG transformations per channel

The following machine data is used to define the channel-specific transformation data
records:
$MC_TRAFO_TYPE_<n>
Maximum two transformation data records of these may be used for transformation TRAANG,
$MC_TRAFO_TYPE_<n> = 1024.
Extended Functions
Example of an axis configuration
0'0&B$;&21)B*(2$;B1$0(B7$% 0'0&$;&21)B*(2$;B$66,*1B7$%
VWJHRPHWU\D[LV>@ ;
QGJHRPHWU\D[LV>@ <
UGJHRPHWU\D[LV>@ =
%<7(! %\WH!
675,1*! WR WR
,ILQFOLQHGD[LVLVDFWLYH 0'0&B75$)2B*(2$;B$66,*1B7$%
0'0&B$;&21)B&+$1$;B1$0(B7$% 0'0&B$;&21)B0$&+$;B86('
&KDQQHO &KDQQHO
&KDQQHO &KDQQHO
VWFKDQQHOD[LV>@ =
QGFKDQQHOD[LV>@ &
UGFKDQQHOD[LV>@ $6
WKFKDQQHOD[LV>@ 08
WKFKDQQHOD[LV>@
WKFKDQQHOD[LV>@
WKFKDQQHOD[LV>@
WKFKDQQHOD[LV>@
WKFKDQQHOD[LV>@
WKFKDQQHOD[LV>@
%\WH!
675,1*! WR
,ILQFOLQHGD[LVLVDFWLYH
0'0$B63,1'B$66,*1B72B0$&+$; 0'01$;&21)B0$&+$;B1$0(B7$%
VWPDFKLQHD[LV>$;@ &
QGPDFKLQHD[LV>$;@ 08
UGPDFKLQHD[LV>$;@ 0=
WKPDFKLQHD[LV>$;@
WKPDFKLQHD[LV>$;@
WKPDFKLQHD[LV>$;@
WKPDFKLQHD[LV>$;@
%\WH! 675,1*!
WR
The configurations highlighted in the figure above apply when TRAANG is active.
Transformation channel axes

MD24110 $MC_TRAFO_AXES_IN_1[0]=4; channel axis number of the inclined axis
MD24110 $MC_TRAFO_AXES_IN_1[1]=1; channel axis number of the longitudinal axis
MD24110 $MC_TRAFO_AXES_IN_1[2]=0 ; ---
Extended Functions
TRAANG active
MD24434 $MC_TRAFO_GEOAX_ASSIGN_TAB_<n>[ 0 ] = 1
See also
TRAANG oblique angle transformation (option) (Page 378)
Angle between longitudinal axis and inclined axis

MD24700 $MC_TRAANG_ANGLE_<m> = <angle>
with -90 < angle < 90 , without 0
The angle is counted positively in the clockwise direction starting at X (see Section
"TRAANG oblique angle transformation (option) (Page 378)": Angle ).
Base offset of the tool zero

The base offset of the tool zero is specified for the valid geometry axes for the active
transformation. The base offset is included with and without selection of the tool length
compensation. Programmed tool length compensations are added to the base tool.
$MC_TRAANG_BASE_TOOL_<n>[ k ] = <base offset>
with k = 0, 1, 2 (1st - 3rd geometry axis)
Note
The tool zero is not converted when the angle is changed.
Extended Functions
Optimization of velocity control

The machine data used to optimize the velocity control in jog mode and in positioning and
oscillation modes:
Speed margin
The machine data sets the speed margin for the compensation movements of the
longitudinal axis:
MD24720 $MC_TRAANG_PARALLEL_VELO_RES_<n> = <value>
<value> Meaning
0.0 The speed margin is determined by the NC depending on the angle of the inclined
axis and the speed capability of the inclined and the longitudinal axis so that the
same speed limitation results in the direction of the longitudinal axis and of the
associated perpendicular (virtual) axis.
> 0.0 Speed margin = <value> * (MD32000 $MA_MAX_AX_VELO of the longitudinal
axis)
Acceleration margin
The machine data sets the acceleration margin for the compensation movements of the
longitudinal axis:
$MC_TRAANG_PARALLEL_ACCEL_RES_<n> = <value>
<value> Meaning
0.0 The acceleration margin is determined by the NC depending on the angle of the
inclined axis and the acceleration capability of the inclined and the longitudinal axis
so that the same acceleration limitation results in the direction of the longitudinal
axis and of the associated perpendicular (virtual) axis.
> 0.0 Acceleration margin = <value> * (MD32300 $MA_MAX_AX_ACCEL of the
longitudinal axis)
M code for transformation change

The specified M code is output for switching the transformation:
MD22534 $MC_TRAFO_CHANGE_M_CODE = <value>
WARNING
No M code is output.
The values 0 to 6, 17 and 30 are not output to the PLC.
Extended Functions
6.4.3 Switch on
The TRAANG transformation is activated in the part program or synchronous action using
the TRAANG command.
Syntax
TRAANG
TRAANG([<>][, <n>])
Meaning
TRAANG: Activate TRAANG with data set 1 and last valid angle
TRAANG(, <n>): Activate TRAANG with data set n and last valid angle
TRAANG(<>): Activate TRAANG with data set 1 and angle
TRAANG(<>, <n>): Activate TRAANG with data set n and angle
<>: Angle of the inclined axis (optional)
Note
Without specifying the angle, the value parameterized in the
machine data:
$MC_TRAANG_ANGLE_<n>, with n = data set number is valid
Range of values: -90 < < + 90
<n>: Data set number (optional)
Range of values: 1, 2
6.4.4 Deactivation
A TRAANG transformation active in the channel is switched-off with:
Activate another transformation, e.g. TRACYL, TRANSMIT, TRAORI
Extended Functions
6.4.5 Boundary conditions

The transformation can be selected and deselected via part program or MDA.
Selection and deselection

An intermediate motion block is not inserted (phases/radii).
A spline block sequence must be terminated.
Tool radius compensation must be deselected.
The current frame is deselected by the control system.
(corresponds to programmed G500).
An active working area limitation is deselected by the control for the axes affected by the
transformation (corresponds to programmed WALIMOF).
An activated tool length compensation is included in the transformation by the control.
Continuous path control and rounding are interrupted.
DRF offsets must have been deleted by the operator.
All axes specified in machine data MD24110 $MC_TRAFO_AXES_IN_n must be
synchronized on a block-related basis (e.g. no traversing instruction with POSA...).
Tool change
Tools may only be changed when the tool radius compensation function is deselected.
Frame
All instructions which refer exclusively to the base coordinate system are permissible (FRAME,
tool radius compensation). Unlike the procedure for inactive transformation, however, a
frame change with G91 (incremental dimension) is not specially treated. The increment to be
traversed is evaluated in the workpiece coordinate system of the new frame - regardless of
which frame was effective in the previous block.
Extensions
When TRAANG is selected and deselected, the assignment between geometry axes and
channel axes can change. The user can apply these geometric contour sections to the axial
frame as a translation, rotation, scaling and mirroring in relation to the x and z plane with
respect to the inclined infeed axis.
For additional information on these frame corrections with transformations, see:
References:
Function Manual, Basic Functions; Axes, Coordinate Systems, Frames (K2)
Extended Functions
Exceptions
Axes affected by the transformation cannot be used
As a preset axis (alarm)
To approach the fixed point (alarm)
For referencing (alarm)
Velocity control
The velocity monitoring function for TRAANG is implemented as standard during preprocessing.
Monitoring and limitation in the main run are activated:
In AUTOMATIC mode, if a positioning or oscillation axis has been programmed that is
involved in the transformation.
On changeover to JOG mode
The monitoring function is transferred again from the main run to block preprocessing if the
preprocessing is re-synchronized with the main run (currently, for example, on changeover
from JOG to AUTOMATIC).
The velocity monitoring function in preprocessing utilizes the dynamic limitations of the
machine better than the monitoring function in the main run.
This also applies to machines on which oblique machining operations are performed.
6.4.6 Programming (G05, G07)
Function
The following functions are available:
Position programming and display in the Cartesian coordinate system
Cartesian calculation of tool offset and work offset
Programming of angles for the inclined axis in the NC program
Approach the starting position for inclined plunge cutting (G07)
Inclined plunge cutting (G05)
Extended Functions
Programming
8
;

1
1
*ULQGLQJGLVF
:RUNSLHFH
Figure 6-14 Machine with inclined infeed axis
Example:

N... ; Program axis for inclined axis
N50 G07 X70 Z40 F4000 ; Approach starting position
N60 G05 X70 F100 ; Oblique plunge-cutting
N...
It is only meaningful to select the function "Cartesian PTP travel" in JOG mode (motion
according to G05) if a transformation is active (TRAANG). Note the value set in MD20140
$MC_TRAFO_RESET_VALUE.
REPOSoffsets must be traversed back in JOG mode in the Cartesian coordinates while
"PTP travel" is not active.
The working area limitation is monitored in JOG mode with active "PTP travel". The axis
is braked before overrunning the working area limitation. If "PTP travel" is not active, the
axis can be traversed right up to the operating range limit.
See also
Cartesian PTP travel (Page 398)
Extended Functions
6.5 Chained transformations
Introduction
It is possible to chain the kinematic transformation described here, with an additional
transformation of the type "Inclined axis":
TRANSMIT
TRACYL
TRAANG (oblique axis)

as described in
References:
Function Manual, Special Functions; 3-Axis to 5-Axis Transformation (F2)
.
Orientation transformations
Universal milling head
Applications
The following is a selection from the range of possible chained transformations:
Grinding contours that are programmed as a side line of a cylinder (TRACYL) using an
inclined grinding wheel, e.g., tool grinding.
Finish cutting of a contour that is not round and was generated with TRANSMIT using an
inclined grinding wheel.
Note
The transformations described below require that individual names are assigned to
machine axes, channels and geometry axes when the transformation is active. Compare
the following machine data:
MD10000: AXCONF_MACHAX_NAME_TAB
MD20080: AXCONF_CHANAX_NAME_TAB
MD20060: AXCONF_GEOAX_NAME_TAB
Besides this, no unequivocal assignments exist.
Axis configuration
The following configuration measures are necessary for a chained transformation:
Assignment of names to geometry axes
Assignment of names to channel axes
Extended Functions

general situation (no transformation active)
Assignment of channel axes to machine axis numbers
Identification of spindle, rotation, modulo for axes
Allocation of machine axis names.
Transformation-specific settings (for individual transformations and for chained
transformations)
Transformation type
axes going into transformation
Assignment of geometry axes to channel axes during active transformation
depending on transformation, rotational position of the co-ordinate system, tool zero
point in relation to the original co-ordinate system, angle of the inclined axis, etc.
Number of transformations
Up to ten transformation data blocks can be defined for each channel in the system. The
machine data names of these transformations begin with $MC_TRAFO .. and end with ... _n,
where n stands for a number between 1 and 10.
Number of chained transformations

Within the maximum of 10 transformations of a channel, a maximum of two chained
transformations may be defined.
Transformation sequence
When configuring the machine data, the data concerning the single transformations (that
may also become part of chained transformations) must be specified before the data
concerning the chained transformations.
Chaining sequence
With chained transformations the second transformation must be "inclined axis" (TRAANG).
Chaining direction
The BCS is the input for the first of the transformations to be chained; the MCS is the output
for the second one.
The supplementary conditions and special cases indicated in the individual transformation
descriptions are also applicable for use in chained transformations.
Extended Functions
6.5.1 Activating chained transformations
TRACON
A chained transformation is activated by:
TRACON(trf, par)
trf:
Number of the chained transformation: 0 or 1 for first/only chained transformation. If
nothing is programmed here, then this has the same meaning as specifying value 0 or 1,
i.e., the first/only transformation is activated 2 for the second chained transformation.
(Values not equal to 0 - 2 generate an error alarm).
par
One or more parameters separated by a comma for the transformations in the chain
expecting parameters, for example, the angle of the inclined axis. If parameters are not
set, the defaults or the parameters last used take effect. Commas must be used to
ensure that the specified parameters are evaluated in the sequence in which they are
expected, if default settings are to be effective for previous parameters. In particular, a
comma is required before at least one parameter, even though it is not necessary to
specify trf. For example: TRACON( , 3.7).TRACON( , 3.7).
If another transformation was previously activated, it is implicitly disabled by means of
TRACON().
6.5.2 Switching off a chained transformation
TRAFOOF
A chained transformation is switched off with TRAFOOF just like any other transformation.
6.5.3 Special characteristics of chained transformations
Tool data
A tool is always assigned to the first transformation in a chain. The subsequent
transformation then behaves as if the active tool length were zero. Only the basic tool
lengths set in the machine data (_BASE_TOOL_) are valid for the first transformation in the
chain.
Example
The chapter "Chained transformations" contains configuration examples for single
transformations and the transformation chains created from them.
See also
Chained transformations (Page 387)
Extended Functions
6.5.4 Persistent transformation
Function
A persistent transformation is always active and has a relative effect to the other explicitly
selected transformations. Other selected transformation are computed as the first chained
transformation in relation to the persistent transformation.
Transformations such as TRANSMIT that must be selected in relation to the persistent
transformation must be parameterized in a chain with the persistent transformation by means
of TRACON. It is the first chained transformation rather than the TRACON transformation which is
programmed in the part program.
For additional programming tips see
References:
Programming Manual, Job Planning; Transformations "Chained Transformation"
Selection and deselection

Persistent transformation is selected via the following machine data:
MD20144 $MC_TRAFO_MODE_MASK, Bit 0 = 1
MD20144 $MC_TRAFO_RESET_VALUE defines persistent transformation.
MD20140 $MC_TRAFO_RESET_VALUE=Number of the transformation data set of the
persistent transformation
In addition the following must be set (i.e. noted):
Bit 0 = 1 (Bit 7 is evaluated)
Bit 7 =0 (MD20140 $MC_TRAFO_RESET_VALUE determines the transformation data set)
MD20112 $MC_START_MODE_MASK (MD20140 $MC_TRAFO_RESET_VALUE)
MD20118 $MC_GEOAX_CHANGE_RESET= TRUE (i.e. geometry axes are reset).
If this additional data is not parameterized correctly,
alarm 14404 is generated.
With TRAFOOF the active TRACON is deselected and the persistent transformation is
automatically selected.
Extended Functions
Effects on HMI operation

As a transformation is always active with the persistent transformation, the HMI user
interface is adapted accordingly for the selection and deselection of transformations:
TRACON on HMI
Accordingly the HMI operator interface does not display TRACON, but the first chain
transformation of TRACON e.g. TRANSMIT . Accordingly, the transformation type of the 1st
chained transformation is returned by the corresponding system variable, i.e. $P_TRAFO
and $AC_TRAFO. Cycles written in TRANSMIT can then be used directly.
TRACOOF on HMI
In accordance with the TRAFOOF programming instruction no transformation is displayed in
the G code list on the HMI user interface. System variables $P_TRAFO and $AC_TRAFO
therefore return a value of 0, the persistent transformation is operative and the BCS and
MCS coordinate systems do not coincide. The displayed MCS position always refers to the
actual machine axes.
System variable
New system variables return the transformation types of the active chained transformations.
Description NCK variable

no transformation active: 0 $P_TRAFO_CHAIN[0]
one transformation active: Type of 1st chained
transformation with TRACON, or type of active
transformation if not TRACON
no transformation active: 0 $P_TRAFO_CHAIN[1]
one transformation active: Type of 2nd chained $AC_TRAFO_CHAIN[1]
transformation with TRACON
are only used if more than 2 transformations are $P_TRAFO_CHAIN[2]
chained. $AC_TRAFO_CHAIN[2] and
These variables presently only return 0. $P_TRAFO_CHAIN[3]
$AC_TRAFO_CHAIN[3]
Display persistent transformation:

$P_TRAFO_CHAIN[0], $AC_TRAFO_CHAI[0]
These settings allow an active transformation to be displayed reliably in the part program or
in cycles.
Difference between a TRACON and the other transformations:
$P_TRAFO, $AC_TRAFO if no transformation is active, or $P_TRAFO_CHAIN[1],
$AC_TRAFO_CHAI[1] is interrogated for a value other than zero.
Extended Functions
Frames
Frame adjustments for selection and deselection of the TRACON are carried out as if there
was only the first chained transformation. Transformations on the virtual axis cease to be
effective when TRAANG is selected.
JOG
The persistent transformation remains in effect when traversing with JOG.
The persistent transformation does not change the principle operating sequences in the
NCK. All restrictions applying to an active transformation also apply to the persistent
transformation.
A RESET command still deselects any active transformation completely; the persistent
transformation is selected again. The persistent transformation is not reselected under error
conditions. A corresponding alarm is generated to indicate the error constellation.
Alarm 14401 or 14404 can be activated when TRAANG is the persistent transformation. When
the persistent transformation is active, other transformation alarms may generated in
response to errors depending on the transformation type selected.
The transformation is deselected implicitly during referencing. A RESET or START command
must be issued after referencing, in order to reselect the persistent transformation.
Example
For a lathe with an inclined additional Y axis, the transformation of the inclined axis should
be part of the machine configuration and therefore does not have to be considered by the
programmer. With TRACYL or TRANSMIT transformations are selected, which must then include
the TRAANG. When the programmed transformations are deactivated, TRAANG is automatically
activated again. In the HMI operator interface TRACYL or TRANSMIT is displayed.
Machine data for a turning machine with Y1 axis inclined in relation to X1 but perpendicular
to Z1.
CANDATA (1)
; Kinematic without transformations
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[1] = "Y2"
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[0] = 1
; Data for TRAANG
MD24100 $MC_TRAFO_TYP_1 = 1024; TRAANG Y1 axis inclined to X1, perpendicular to
Z1
MD24110 $MC_TRAFO_AXES_IN_1[0]=2
Extended Functions
MD24110 $MC_TRAFO_AXES_IN_1[2] = 3
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]=1
MD24700 $MC_TRAANG_ANGLE_1 = 60
MD24720 $MC_TRAANG_PARALLEL_VELO_RES_1 = 0.2
MD24721 $MC_TRAANG_PARALLEL_ACCEL_RES_1 = 0.2
; Definition of persistent transformation
MD20144 $MC_TRAFO_MODE_MASK = 1
MD20140 $MC_TRAFO_RESET_VALVUE= 1
MD20110 $MC_RESET_MODE_MASK = 'H01'
MD20112 $MC_START_MODE_MASK = 'H80'
MD20140 $MC_TRAFO_RESET_VALUE
MD20118 $MC_GEOAX_CHANGE_RESET= TRUE
; Data for TRANSMIT, TRACYL
MD24911 $MC_TRANSMIT_POLE_SIDE_FIX_1 = 1 ; also 2, causes alarm 21617
MD24200 $MC_TRAFO_TYP_2 = 257
MD24220 $MC_TRAFO_GEOAX_ASSIGN_TAB_2[0] =1
Extended Functions
; Data for TRACON
; TRACON chaining TRANSMIT 514/TRAANG(Y1 axis inclined in relation to X1)
MD24995 $MC_TRACON_CHAIN_1[0] = 3
; TRACON chaining TRANSMIT 257/TRAANG(Y1 axis inclined in relation to X1)
MD24996 $MC-TRACON_CHAIN_2[0] = 2
MD24996 $MC-TRACON_CHAIN_2[1] = 1
M17
; matching part program:
$TC_DP1[1,1]=120 ; tool type
$TC_DP2[1,1] = 0
$TC_DP3[1,1]=3 ; length compensation vector
$TC_DP4[1,1]=25
$TC_DP5[1.1] =5
$TC_DP6[1,1]= 2; Radius; tool radius
; transformation change:
N1000 G0 X0 Y=0 Z0 A80 G603 SOFT G64
N1010 N1020 X10 Y20 Z30 ; TRAANG(,1) not possible, since automatically selected
N1110 TRANSMIT(1) N1120 X10 Y20 Z30N1130 Y2=0 ; TRACON(2) not necessary, since
translated automatically
N1210 TRAFOOF ; TRAANG(,1) not necessary, since translated automatically
N1220 X10 Y20 Z30
M30
Extended Functions
6.5.5 Axis positions in the transformation chain
Function
System variables having the following content are provided for machines with system or
OEM transformations, especially for chained transformations (TRACON):
Type System variable Meaning

REAL $AA_ITR[ax,n] Current setpoint value at output of the nth transformation
REAL $AA_IBC[ax] Current setpoint value of a cartesian axis
REAL $VA_ITR[ax,n] Current actual value at output of the nth transformation
REAL $VA_IBC[ax] Current cartesian BCS encoder position of an axis
REAL $VA_IW[ax] Current WCS actual value of an axis
REAL $VA_IB[ax] Current BCS encoder position of an axis
The following must be observed with reference to the control system responses:
POWER ON
The encoder position has the value 0 for not-referenced axes. The encoder actual values
are inverse-transformed accordingly for the $VA variables.
RESET
An active transformation can change in RESET, which has a direct influence on the
values of the system variables. An active transformation which is active again after
RESET, is deactivated for a short duration and then reactivated. This has a direct
influence on the position variables. The values of variables can change.
Via the variable:
$AC_STAT == 0
this status can be queried in synchronous actions.
Extended Functions
$AA_ITR[ <axis>, <transformer layer> ]

The $AA_ITR[ax,n] variable determines the setpoint position of an axis at the output of the
nth chained transformation.
\ \ \ \ \
[ [ [ [ [
] ] ] ] ]
%&6 7UDQVI 7UDQVI 7UDQVI 7UDQVI 0&6

/D\HU
/D\HU
/D\HU
/D\HU
/D\HU
Figure 6-15 Transformer layer
Transformer layer
The 2nd index of the variable corresponds to the transformer layer in which the positions are
tapped:
Transformer layer 0: The positions correspond to the BCS positions, i.e.:
$AA_ITR[x,0] == $AA_IB[x]
Transformer layer 1: Setpoint positions at output of 1st transformation
Transformer layer 2: Setpoint positions at output of 2nd transformation
Transformer layer 3: Setpoint positions at output of 3rd transformation
Transformer layer 4: Setpoint positions at output of 4th transformation, i.e.
$AA_ITR[x,4] == $AA_IM[x]
If one or more transformations of the transformer chain are missing, the highest layers
continue to deliver the same values. If, e.g. Transformer 3 and Transformer 4 are missing,
this corresponds to:
$AA_ITR[x,2] = $AA_ITR[x,3] = $AA_ITR[x,4] = $AA_IM[x]
If the transformations are shut off via TRAFOOF or in RESET, the Layers 0 to 4 fuse together
and the variable always delivers the BCS value (Layer 0) in this case.
Axis
Either a geometry, channel or a machine axis name is permissible as the 1st index of the
variable. The assignment of the channel axes to the geometry axes corresponding to the 0
layer takes place during the programming of geometry axis name in each transformer layer.
Using geometry axis names is meaningful only if the geometry axes are not switched over.
Otherwise it is always better to use channel axis names.
Extended Functions
$AA_IBC[ <axis>]
The variable $AA_IBC[ax] determines the setpoint position of a cartesian axis lying between
BCS and MCS. If an axis is cartesian at the output of the nth transformation, then this output
value is delivered. If the corresponding axis at the output of all transformations is not
cartesian, then the BCS value including all BCS offsets of the axis are determined.
If TRACON responds to an axis as cartesian, then its MCS value is delivered. The used axis
name can be a geometry, channel or a machine axis name.
$VA_ITR[ <axis>, <transformer layer> ]

The variable $VA_ITR[ax,n] determines the encoder position of an axis at the output of the
nth chained transformation.
$VA_IBC[ <axis>]
The variable $VA_IBC[ax] determines the encoder position of a cartesian axis lying between
BCS and MCS. The used axis name can be a geometry, channel or a machine axis name.
If an axis at the output of the nth transformation is cartesian, then this output value is
delivered. If the corresponding axis at the output of all transformations is not cartesian, then
the BCS value of the axis is determined.
$VA_IW[ <axis>]
The variable $VA_IW[ax] determines the encoder position of an inverse-transformed axis in
WCS. The WCS value contains all axis-related superimposition portions (DRF, AA_OFF, ext.
zero offset etc.) and offset values (CEC, etc.).
$VA_IB[ <axis>]
The variable $VA_IB[ax] determines the inverse-transformed encoder position of an axis in
BCS. The BCS value contains all axis-related superimposition portions (DRF, AA_OFF, ext.
zero offset etc.) and offset values (CEC, etc.).
Note
$VA_ITR$, VA_IBC, $VA_IW, $VA_IB
The value of the variable does not change while reading the variable within an IPO cycle,
although the actual value could have changed.
In active transformations, one must consider that the transformation of the actual values into
BCS in the IPO cycle can be very time-consuming. In this case one must set an adequate
IPO cycle.
Extended Functions
6.6 Cartesian PTP travel
Function
This function can be used to approach a Cartesian position with a synchronized axis
movement.
It is particularly useful in cases where, for example, the position of the joint is changed,
causing the axis to move through a singularity.
When an axis passes through a singularity, the feed velocity would normally be reduced or
the axis itself overloaded.
Note
MD24100 $MC_TRAFO_TYPE_1 must be set to the transformation type described in TE4.
The function can only be used meaningfully in conjunction with an active transformation.
Furthermore, the "Cartesian PTP travel" function may only be used in conjunction with the
G0 and G1 commands. Alarm 14144 "PTP travel not possible" is otherwise output.
When PTP is active, axes in the transformation, e.g. which are traversed using POS, cannot
be simultaneously positioning axes. Alarm 17610 is activated to prevent this error.
Activation
The function is activated when the PTP command is programmed.
The function can be deactivated again with the CP command. Both these commands are
contained in G group 49.
PTP command: The programmed Cartesian position is approached with a synchronized
axis motion (PTP=point-to-point)
CP command: The programmed Cartesian point is approached with a path movement
(default setting), (CP=continuous path)
PTPG0 command: The programmed Cartesian PTP motion is performed automatically
with each G0 block. The CP command is then set again.
Power On
After Power on traversing mode CP is automatically set for axis traversal with transformation.
MD20152 $MC_GCODE_RESET_VALUES[48] can be used to switch the default setting to
cartesian PTP travel.
Extended Functions
Reset
MD20152 $MC_GCODE_RESET_MODE[48] (group 49) defines which setting is active after
RESET/end of part program.
MD=0: Settings are effected in accordance with machine data
MD20150 $MC_GCODE_RESET_VALUES[48]
MD=1: Active setting remains valid
Selection
The setting MD20152 $MC_GCODE_RESET_MODE[48] =0, with MD20150
$MC_GCODE_RESET_VALUES[48] can activate the following:
MD=2:
Cartesian PTP travel as previously or
MD=3:
PTPG0, traverse only G0 blocks with PTP automatically and then switch over to CP again
The following should be noted with respect to tool movement and collision:
As the PTP command can produce significantly different tool movements to the CP
command, any pre-existing subprograms which have been written independently of the
active transformation must be adapted to take account of the risks of collision when
TRANSMIT is active. This applies particularly in the case of command PTPG0.
Machine axes always traverse the shortest possible path in response to TRANSMIT and
PTP. Minor displacements in the block end point can cause the rotary axis to rotate by -
179.99 instead of + 179.99, even though the block end point has hardly changed.
The following combinations with other NC functions are not legal:
No tool radius compensation (TRC) may be active with PTP.
G0 and G41 do not exclude each other in principle. However, an active PTP generates
different contours to those computed for the TRC, resulting in the activation of a TRC
alarm.
With PTPG0 , for active tool radius compensation (TRC), traverse is by CP.
Since G0 and G41 do not exclude each other, switch-over to CP is done automatically
when tool radius compensation is active. The radius compensation therefore works on
the basis of clearly defined contours.
PTP does not permit smooth approach and retraction (SAR).
SAR requires a contour in order to construct approach and retraction motion. This
information is not available with PTP.
Extended Functions
With PTPG0, CP travel is used for smooth approach and retraction (SAR).
SAR requires a contour in order to construct approach and retraction motion and to be
able to lower and raise tangentially. The blocks required for this purpose are therefore
traversed with the CP command. The G0 blocks up to the actual approach contour are
executed with PTP and therefore quickly. The same applies to the retract blocks.
PTP does not permit cutting cycles like CONTPRON, CONTDCON
Stock removal cycles require a contour to construct the cut segmentation. This
information is not available with PTP. Alarm 10931 "Error in cut compensation" is
generated in response.
When PTPG0 is selected, the CP command is applied in cutting cycles such asCONTPRON,
CONTDCON. Stock removal cycles require a contour to construct the cut segmentation. The
blocks required for this purpose are traversed with the CP command.
Chamfer and rounding are ignored.
An axis override in the interpolation must not change during the PTP contour section.
This applies, for example, to LIFTFAST, fine tool offset, coupled motion TRAILON and
tangential follow-up TANGON.
In PTP blocks
compressor is automatically deselected because it is not compatible with PTP.
G643 is automatically switched over to G642.
Transformation axes must not be configured simultaneously as positioning axes.
Special features
Please take account of the following basic rules with respect to the basic coordinate system:
Smoothing G642 is always interpreted in the machine coordinate system and not (as
usual) in the cartesian basic coordinate system.
G641 determines the smoothing action as a function of the fictitious path calculated from
the machine axis coordinates.
An F value input with G1 refers to the fictitious path calculated from the machine axis
coordinates.
Block search
TRANSMIT during block search can result in different machine axis positions for the same
Cartesian position, if a program section is executed with block search.
Alarms
An illegal action, which may result in a conflict, is rejected with the following alarms:
Alarm 14144: If TRC is selected or activated in PTP. Likewise in PTP with soft approach and
retraction (SAR) or PTP without the required G0 and G1 blocks.
Extended Functions
Alarm 10753: With PTPG0 and active TRC an internal switch-over to CP is done in order to
allow the tool radius correction to be performed correctly.
Alarm 10754: Still possible in case of conflict.
Alarm 10744: With PTPG0, CP travel is used for smooth approach and retraction (SAR), in
order to ensure correct processing of soft approach and retraction.
Alarm 17610: Transformation axes must not be configured simultaneously as positioning
axes traversed by means of POS.
Note
For further information about programming plus programming examples, please see:
References:
Programming Manual, Job Planning; Section Transformations, "Cartesian PTP Travel"
6.6.1 Programming of position

Generally speaking, a machine position is not uniquely defined solely by a position input with
Cartesian coordinates and the orientation of the tool. Depending on the kinematics of the
relevant machine, the joint may assume up to 8 different positions. These joint positions are
specific to individual transformations.
STAT address
A Cartesian position must be convertible into unique axis angles. For this reason, the
position of the joints must be entered in the STAT address.
The STAT address contains a bit for every possible setting as a binary value. The meaning of
these bits is determined by the relevant transformation.
As regards the transformations contained in the publication "Handling Transformation
Package (TE4)", the bits are assigned to different joint positions, as shown in the figure
above.
Extended Functions
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Figure 6-16 Position bits for Handling Transformation Package
Note
It is only meaningful to program the STAT address for "Cartesian PTP travel", since changes
in position are not normally possible while an axis is traversing with active transformation.
The starting point position is applied as the destination point for traversal with the CP
command.
6.6.2 Overlap areas of axis angles
TU address
In order to approach axis angles in excess of 180 without ambiguity, the information must
be programmed in the TU (turn) address. The TU address thus represents the sign of the
axis angles. This allows an axis angle of || < 360 to be traversed without ambiguity.
Variable TU contains a bit, which indicates the traversing direction for every axis involved in
the transformation.
TU bit=0: 0 < 360
TU bit=1: 360 < < 0
The TU bit is set to 0 for linear axes.
In the case of axes with a traversing range >360, the axis always moves across the
shortest path, because the axis position cannot be specified uniquely by the TU information.
If no TU is programmed for a position, the axis always traverses via the shortest possible
route.
Extended Functions
6.6.3 Examples of ambiguities of position

The kinematics for a 6axis joint have been used to illustrate the ambiguities caused by
different joint positions.
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Figure 6-17 Ambiguity in overhead area
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Figure 6-18 Ambiguity of top or bottom elbow
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Figure 6-19 Ambiguity of axis B1
Extended Functions
6.6.4 Example of ambiguity in rotary axis position

The rotary axis position shown in the following diagram can be approached in the negative or
positive direction. The direction is programmed under address A1.
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Figure 6-20 Ambiguity in rotary axis position
6.6.5 PTP/CP switchover in JOG mode

In JOG mode, the transformation can be switched on and off via a channel-specific NC/PLC
interface signal. This control signal is only effective in JOG mode when the transformation is
active.
After returning to AUTO mode, the state which was last active before switchover is restored.
NC/PLC interface signals

Request to switch the traversing type:
DB21, ... DBX29.4 (activate PTP travel)
Feedback from the active traversing type:
DB21, ... DBX317.6 (PTP travel active)
Operating mode change

The "Cartesian PTP travel" function is only useful in the AUTO and MDI modes of operation.
The CP setting is automatically activated if the operating mode is switched to JOG. If the
mode is then switched back to AUTO or MDI, the mode that was last active in either mode is
made active again.
REPOS
The setting for "Cartesian PTP travel" is not altered during re-positioning. If PTP was set in
the interruption block, then repositioning also takes place with PTP. For an inclined axis
"TRAANG", only CP travel is active in REPOS mode.
Extended Functions
6.7 Cartesian manual travel (optional)
Note
The "Handling transformation package" option is necessary for the "Cartesian manual travel"
function.
Function
The "Cartesian manual travel" function, as a reference system for JOG mode, allows axes to
be set independently of each other in the following Cartesian coordinate systems:
Basic coordinate system (BCS)
Workpiece coordinate system (WCS)
Tool coordinate system (TCS)
Adjustment and activation is done using machine data:
MD21106 $MC_CART_JOG_SYSTEM (coordinate systems for Cartesian JOG)
Bit Meaning
0 Basic coordinate system
1 Workpiece coordinate system
2 Tool coordinate system
Note
The workpiece coordinate system has been shifted and rotated compared to the basic
coordinate system via frames.
Reference:
Function Manual Basic Functions; Axes, Coordinate Systems, Frames (K2)
Representation of the reference system in the coordinate system:
WCS = Workpiece zero TCS = Tool reference point
Extended Functions
Selecting reference systems

For JOG motion, one of the three reference systems can be specified separately not only for
the translation (coarse offset) with geometry axes, but also for the orientation with orientation
axes via the following setting data:
SD42650 $SC_CART_JOG_MODE
If more than one bit is set for the translation or orientation reference system, or when an
attempt is made to set a reference system which was not released by the MD21106
$MC_CART_JOG_SYSTEM, the alarm 14148 "Reference system for Cartesian manual
travel not allowed" will be generated.
Translation
A translation movement can be used to move the tool tip (TCP) in parallel and 3-dimensional
to the axes of the reference system. The traversing movement is made via the VDI signals of
the geometry axes.
Machine data MD24120$MC_TRAFO_GEOAX_ASSIGN_TAB_x[n] is used to assign the
geometry axes. Simultaneous traversing in more than one direction permits the execution of
movements that lie parallel to the directions of the reference system.
Translation in the BCS

The basic coordinate system (BCS) describes the Cartesian zero of the machine.
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Figure 6-21 Cartesian manual travel in the basic coordinate system (translation)
Extended Functions
Translation in the WCS

The workpiece coordinate system (WCS) lies in the workpiece zero. The workpiece
coordinate system can be shifted and rotated relative to the reference system via frames. As
long as the frame rotation is active, the traversing movements correspond to the translation
of the movements in the basic coordinate system.
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Figure 6-22 Cartesian manual travel in the workpiece coordinate system (translation)
Translation in the TCS

The tool coordinate system (TCS) lies in the tool tip. Its direction depends on the current
setting of the machine, since the tool coordinate system moves during the motion.
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Figure 6-23 Cartesian manual travel in the tool coordinate system (translation)
Extended Functions
Translation and orientation in the TCS simultaneously

If translation and orientation movements are executed at the same time, the translation is
always traversed corresponding to the current orientation of the tool. This permits infeed
movements that are made directly in the tool direction or movements that run perpendicular
to tool direction.
Orientation
The tool can be aligned to the component surface via an orientation movement. The
orientation movement is given control from the PLC via the VDI signals of the orientation
axes (DB21, ... DBB321).
Several orientation axes can be traversed simultaneously. The virtual orientation axes
execute rotations around the fixed axes of the relevant reference system.
The rotations are identified according to the RPY angles.
A angle: Rotation around the Z axis
B angle: Rotation around the Y axis
C angle: Rotation around the X axis
Programming rotations:
The user can define how rotations are to be executed using the current G codes of group 50
for orientation definition
Specifying ORIEULER, ORIRPY, ORIVIRT1 and ORIVIRT2.
With ORIVIRT1, rotation is executed according to MD21120 $MC_ORIAX_TURN_TAB_1.
The orientation axes are assigned to the channel axes via machine data: MD24585
$MC_TRAFO5_ORIAX_ASSIGN_TAB_1.
The direction of rotation is determined according to the "right hand rule". The thumb points in
the direction of the rotary axis. The finger stipulates the positive direction of rotation.
Orientation in WCS
The rotations are made around the defined directions of the workpiece coordinate system. If
frame rotation is active, the movements correspond to the rotations in the basic coordinate
system.
Extended Functions
Orientation in BCS
The rotations are made around the defined directions of the basic coordinate system.
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Figure 6-25 Cartesian manual travel in the basic coordinate system, orientation angle B
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Figure 6-26 Cartesian manual travel in the basic coordinate system, orientation angle C
Extended Functions
Orientation in TCS
The rotations are around the moving directions in the tool coordinate system. The current
homing directions of the tool are always used as rotary axes.
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Figure 6-27 Cartesian manual travel in the tool coordinate system, orientation angle A
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Figure 6-29 Cartesian manual travel in the tool coordinate system, orientation angle C
Extended Functions
The "Cartesian manual travel" function can only be executed if the transformation is active in
the NC: DB21, ... DBX33.6 == 1 ("transformation active")
The following supplementary conditions must be observed:
"Handling transformation package" option with 5-axis or 6-axis transformation is set
Virtual orientation axes must be defined via the following machine data:
MD24585 $MC_TRAFO5_ORIAX_ASSIGN_TAB_1[n]
DB21, ... DBX29.4 == 0 (activate PTP travel)
MD21106 $MC_CART_JOG_SYSTEM > 0
Table 6- 2 Conditions for Cartesian manual travel
Transformation in Prog. traversing type DB21, ... DBX29.4 DB21, ... DBX33.6
program active "Activate PTP travel" "Transformation active"
(TRAORI..)
FALSE Not active Not active 0
TRUE CP 0 1
TRUE CP 1 0
TRUE PTP 0 1
TRUE PTP 1 0
The G code PTP/CP currently active in the program does not affect Cartesian manual travel.
The NC/PLC interface signals are interpreted in the channel DB for geometry and orientation
axes.
Activation
The reference system for Cartesian manual travel is set as follows:
The Cartesian manual travel function is activated with the following machine data:
MD21106 $MC_CART_JOG_SYSTEM > 0
The BCS, WCS or TCS reference systems are enabled via MD 21106
$MC_CART_JOG_SYSTEM.
JOG traverse motion via SD42650 SC_CART_JOG_MODE
Standard behavior as before: Bits 0 to 2 = 0, bits 8 to 10 = 0.
Reference system for translation via bits 0-2 and the reference system for orientation via
bits 8-10.
If not all of the bits are set to 0, the process uses the new function. The reference
systems for translation and orientation may be set independently.
SD42650 $SC_CART_JOG_MODE (only set one bit):
Extended Functions
6.8 Activating transformation machine data via part program/softkey
SD42650 $SC_CART_JOG_MODE
Bit 11 - Bit 10 Bit 9 Bit 8 Bit 7 - Bit 2 Bit 1 Bit 0
bit 15 bit 3
Reserved Orientation Orientation Orientation Reserved Translation Translatio Translation
in the TCS in the in the BCS in the TCS n in the in the BCS
WCS WCS
Combining reference systems

The table below shows all the combination options for reference systems.
SD42650 $SC_CART_JOG_MODE Reference system for

Bit 10 Bit 9 Bit 8 Bit 2 Bit 1 Bit 0 Orientation Translation
0 0 0 0/1 0/1 0/1 Standard Standard
Standard Standard Standard 0 0 0 Standard Standard
0 0 1 0 0 1 BCS BCS
0 0 1 0 1 0 BCS WCS
0 0 1 1 0 0 BCS TCS
0 1 0 0 0 1 WCS BCS
0 1 0 0 1 0 WCS WCS
0 1 0 1 0 0 WCS TCS
1 0 0 0 0 1 TCS BCS
1 0 0 0 1 0 TCS WCS
1 0 0 1 0 0 TCS TCS
6.8.1 Functionality
Transformation MD can now be activated by means of a program command softkey, i.e.
these can, for example, be written from the parts program, thus altering the transformation
configuration completely.
Up to ten different transformations can be set in the control system. The transformation type
is set in the following machine data:
MD24100 $MC_TRAFO_TYPE_1
up to
MD24460 $MC_TRAFO_TYPE_10.
Extended Functions
Characteristics
Transformation machine data are NEWCONFIG effective.
The protection level is now 7/7 (KEYSWITCH_0), which means that data can be modified
from the NC program without any particular authorization.
Provided that no transformation is selected (activated) when a NEWCONF command is issued
(regardless whether via the NEWCONF NC program command, the HMI or implicitly
following Reset or end of program), the machine data listed above can be altered without
restriction and then activated.
Of particular relevance is that new transformations can be configured or existing
transformations replaced by one of a different type or deleted, since the modification options
are not restricted to re-parameterization of existing transformations.
6.8.2 Constraints
Change machine data

The machine data which affect an active transformation may not be altered; any attempt to
do so will generate an alarm.
These are generally all machine data assigned to a transformation via the associated
transformation data group. Machine data that are included in the group of an active
transformation, but not in use, can be altered (although this would hardly be meaningful). For
example, it would be possible to change machine data MD24564
$MC_TRAFO5_NUTATOR_AX_ANGLE_n for an active transformation with MD24100
$MC_$MC_TRAFO_TYPE = 16 (5-axis transformation with rotatable tool and two mutually
perpendicular rotary axes A and B) since this particular machine data is not involved in the
transformation.
Please note that machine data MD21110 $MC_X_AXIS_IN_OLD_X_Z_PLANE may not be
altered for an active orientation transformation.
Note
In the case of a program interruption (Repos, deletion of distance to go, ASUBs, etc.), the
control system requires a number of different blocks that have already been executed for the
repositioning operation. The rule forbidding the machine data of an active transformation to
be altered also refers to these blocks.
Example:
Two orientation transformations are set via machine data, e.g. MD24100
$MC_TRAFO_TYPE_1 = 16, MD24200 $MC_TRAFO_TYPE_2 = 18.
Assume that the second transformation is active when the NEWCONFIG command is
executed. In this case, all machine data that relate only to the first transformation may be
changed, e.g.:
MD24500 $MC_TRAFO5_PART_OFFSET_1
Extended Functions
but not, for instance:

MD24650 $MC_TRAFO5_BASE_TOOL_2
or
MD21110 $MC_X_AXIS_IN_OLD_X_Z_PLANE
Furthermore, another transformation (TRANSMIT) can be set, for example with MD24300
$MC_TRAFO_TYPE_3 = 256 and can be parameterized with additional machine data.
Defining geometry axes

Geometry axes must be defined before starting the control system with the following
machine data:
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_X[n]
or
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[n]
Changing the assignment

The assignment of a transformation data set to a transformation is determined by the
sequence of entries in MD24100 $MC_TRAFO_TYPE_X. The first entry in the table is
assigned to the first transformation data set, and accordingly the second entry to the second
data set. This assignment may (and can) not be altered for an active transformation.
Example:
Three transformations are set, two orientation transformations and one Transmit
transformation, e.g.
MD24100 $MC_TRAFO_TYPE_1 = 16
; orientation transformation, 1st orientation trafo data set
MD24200 $MC_TRAFO_TYPE_2 = 256 : Transmit transformations
; orientation transformation, 2nd orientation trafo data set
The first data set for orientation transformations is assigned to the first transformation
(equaling the first orientation transformation) and the second transformation data set to the
third transformation (equaling the second orientation transformation).
If the third transformation is active when the NEWCONFIG command is executed, it is not
permissible to change the first transformation into a transformation of another group (e.g.
TRACYL) since, in this case, the third transformation would then not become the second
orientation transformation, but the first.
In the above example, however, it is permissible to set another orientation transformation for
the first transformation (e.g. using MD24100 $MC_TRAFO_TYPE_1 = 32) or a
transformation from another group as the first transformation (e.g. using $MD24100
$MC_TRAFO_TYPE_1 = 1024, TRAANG), if the second transformation is changed into an
orientation transformation at the same time, e.g. with MD24200 $MC_TRAFO_TYPE_2 = 48.
Extended Functions
6.8.3 Control response to power ON, mode change, RESET, block search, REPOS
With the aid of the following machine data it is possible to select a transformation
automatically in response to RESET (i.e. at end of program as well) and/or on program start:
and
This may result in the generation of an alarm, for example, at the end or start of a program, if
the machine data of an active transformation has been altered.
To avoid this problem when re-configuring transformations via an NC program, we therefore
recommend that NC programs are structured as follows:

N10 TRAFOOF() ; Select a possibly still active
transformation
N20$MC_TRAFO5_BASE_TOOL_1[0]=0 ; Enter machine data
N30$MC_TRAFO5_BASE_TOOL_1[0]=3
N40$MC_TRAFO5_BASE_TOOL_1[0]=200
N130 NEWCONF ; Newly entered machine data
; Transfer
N140 M30
6.8.4 List of machine data affected

Machine data which can be made NEWCONFIG compatible are listed below.
All transformations
Machine data which are relevant for all transformations:
MD24100 $MC_TRAFO_TYPE_1 to MD24480 $MC_TRAFO_TYPE_10
MD24110 $MC_TRAFO_AXES_IN_1 to MD24482 $MC_TRAFO_AXES_IN_10
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 to
MD24484 $MC_TRAFO_GEOAX_ASSIGN_TAB_10
Extended Functions
Orientation transformations
Machine data which are relevant for orientation transformations:
MD24550 $MC_TRAFO5_BASE_TOOL_1 and
MD24650 $MC_TRAFO5_BASE_TOOL_2
MD24558 $MC_TRAFO5_JOINT_OFFSET_1 and
MD24658 $MC_TRAFO5_JOINT_OFFSET_2
MD24500 $MC_TRAFO5_PART_OFFSET_1 and
MD24600 $MC_TRAFO5_PART_OFFSET_2
MD24510 $MC_TRAFO5_ROT_AX_OFFSET_1 and
MD24610 $MC_TRAFO5_ROT_AX_OFFSET_2
MD24520 $MC_TRAFO5_ROT_SIGN_IS_PLUS_1 and
MD24620 $MC_TRAFO5_ROT_SIGN_IS_PLUS_2
MD 24530: TRAFO5_NON_POLE_LIMIT_1 and
MD24630 $MC_TRAFO5_NON_POLE_LIMIT_2
MD24540 $MC_TRAFO5_POLE_LIMIT_1 and
MD24640 $MC_TRAFO5_POLE_LIMIT_2
MD24570 $MC_TRAFO5_AXIS1_1 and
MD24670 $MC_TRAFO5_AXIS1_2
MD24572 $MC_RAFO5_AXIS2_1 and
MD24672 $MC_TRAFO5_AXIS2_2
MD24574 $MC_TRAFO5_BASE_ORIENT_1 and
MD24674 $MC_TRAFO5_BASE_ORIENT_2
MD24562 $MC_TRAFO5_TOOL_ROT_AX_OFFSET_1 and
MD24662 $MC_TRAFO5_TOOL_ROT_AX_OFFSET_2
MD24564 $MC_TRAFO5_NUTATOR_AX_ANGLE_1 and
MD24664 $MC_TRAFO5_NUTATOR_AX_ANGLE_2
MD24566 $MC_TRAFO5_NUTATOR_VIRT_ORIAX_1 and
MD24666 $MC_TRAFO5_NUTATOR_VIRT_ORIAX_2
Transmit transformations
Machine data which are relevant for Transmit transformations:
MD24920 $MC_TRANSMIT_BASE_TOOL_1 and
MD24970 $MC_TRANSMIT_BASE_TOOL_2
MD24900 $MC_TRANSMIT_ROT_AX_OFFSET_1 and
MD24950 $MC_TRANSMIT_ROT_AX_OFFSET_2
Extended Functions
MD24910 $MC_TRANSMIT_ROT_SIGN_IS_PLUS_1 and

MD24960 $MC_TRANSMIT_ROT_SIGN_IS_PLUS_2
MD24911 MC_RANSMIT_POLE_SIDE_FIX_1 and
Tracyl transformations
Machine data which are relevant for Tracyl transformations:
MD24820 $MC_TRACYL_BASE_TOOL_1 and
MD24870 $MC_TRACYL_BASE_TOOL_2
MD24800 $MC_TRACYL_ROT_AX_OFFSET_1 and
MD24850 $MC_TRACYL_ROT_AX_OFFSET_2
MD24810 $MC_TRACYL_ROT_SIGN_IS_PLUS_1 and
MD24870 $MC_TRACYL_ROT_SIGN_IS_PLUS_2
MD24808 $MC_TRACYL_DEFAULT_MODE_1 and
MD24858 $MC_TRACYL_DEFAULT_MODE_2
Inclined axis transformations

Machine data which are relevant for inclined axis transformations:
MD24710 $MC_TRAANG_BASE_TOOL_1 and
MD24760 $MC_TRAANG_BASE_TOOL_2
MD24700 $MC_TRAANG_ANGLE_1 and
MD24750 $MC_TRAANG_ANGLE_2
MD24720 $MC_TRAANG_PARALLEL_VELO_RES_1 and
MD24770 $MC_TRAANG_PARALLEL_VELO_RES_2
MD24721 $MC_TRAANG_PARALLEL_ACCEL_RES_1 and
MD24771 $MC_TRAANG_PARALLEL_ACCEL_RES_2
Chained transformations
Machine data which are relevant for chained transformations:
MD24995 $MC_TRACON_CHAIN_1 and
MD24996 $MC_TRACON_CHAIN_2
MD24997 $MC_TRACON_CHAIN_3 and
MD24998 $MC_TRACON_CHAIN_4
Extended Functions
6.9 Constraints
Persistent transformation
Machine data which are relevant for persistent transformations:
MD20144 $MC_TRAFO_MODE_MASK
MD20110 $MC_RESET_MODE_MASK and
Not transformation-specific
Machine data that are not transformation-specific. they are not uniquely assigned to a
particular transformation data set or they are relevant even when a transformation is not
active:
MD21110 $MC_X_AXIS_IN_OLD_X_Z_PLANE
MD21090 $MC_ MAX_LEAD_ANGLE
MD21092 $MC_ MAX_TILT_ANGLE
MD21100 $MC_ORIENTATION_IS_EULER
6.9 Constraints

Two transformations can be chained.
However, not just any transformation can be chained to another one.
In this case, the following restrictions apply:
The first transformation of the chain has to be one of the following transformations:
Orientation transformation (3-axis, 4-axis, 5-axis transformations, universal milling
head).
Transmit
Surface line transformation
Inclined axis
The second transformation must be aninclined axis transformation.
Only two transformations may be chained.
It is allowed (for test purposes, for instance), to enter only a single transformation into the
chaining list.
Extended Functions
6.10 Examples
6.10 Examples
6.10.1 TRANSMIT
The following example relates to the configuration illustrated in "Figure 6-30 Groove with
groove wall offset, cylinder coordinates (Page 423)" and shows the sequence of main steps
required to configure the axes and activate TRANSMIT.
; General axis configuration for rotation

MD20060 $MC_AXCONF_GEOAX_NAME_TAB[0]="X" ; Geometry axis
MD20060 $MC_AXCONF_GEOAX_NAME_TAB[1]="Y" ; Geometry axis
MD20060 $MC_AXCONF_GEOAX_NAME_TAB[2]="Z" ; Geometry axis
MD20060 $MC_AXCONF_GEOAX_ASSIGN_TAB[0] = 1 ; X as channel axis 1
MD20060 $MC_AXCONF_GEOAX_ASSIGN_TAB[1] = 0 ; Y no channel axis
MD20060 $MC_AXCONF_GEOAX_ASSIGN_TAB[2] = 2 ; Z as channel axis 2
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[4] = " "
MD20070 $MC_AXCONF_MACHAX_USED[0] = 2 ; XC as machine axis 2
MD20070 $MC_AXCONF_MACHAX_USED[1]=3 ; ZC as machine axis 3
MD20070 $MC_AXCONF_MACHAX_USED[2]=1 ; CC as machine axis 1
MD20070 $MC_AXCONF_MACHAX_USED[3] = 4 ; ASC as machine axis 4
MD20070 $MC_AXCONF_MACHAX_USED[3] = 0 ; empty
MD20070 $MA_SPIND_ASSIGN_TO_MACHAX[AX1]= 1 ; C is spindle 1
MD20070 $MA_SPIND_ASSIGN_TO_MACHAX[AX2]= 0 ; X is no spindle
MD20070 $MA_SPIND_ASSIGN_TO_MACHAX[AX3]= 0 ; Z is no spindle
MD20070 $MA_SPIND_ASSIGN_TO_MACHAX[AX4]= 2 ; AS is spindle 2
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[0]="CM" ; 1. Machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[1]="XM" ; 2. Machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[2]="ZM" ; 3. Machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[3]="ASM" ; 4. Machine axis
Extended Functions
6.10 Examples
; prepare for TRANSMIT (as first and only transformation)

$MA_ROT_IS_MODULO[3] = TRUE ; c as modulo axis
MD24100 $MC_TRAFO_TYPE_1 = 256 ;TRANSMIT transformation
MD24110 $MC_TRAFO_AXES_IN_1[0] = 1 ; channel axis perpendicular to rotary
axis
MD24110 $MC_TRAFO_AXES_IN_1[1] = 3 ; channel rotary axis
MD24110 $MC_TRAFO_AXES_IN_1[2]=2 ; channel axis parallel to rotary axis
MD24120$MC_TRAFO_GEOAX_ASSIGN_TAB_1[0] ; 1. channel axis becomes GEOAX X
=1
MD24120 ; 2. channel axis becomes GEOAX Y
$MC_TRAFO_GEOAX_ASSIGN_TAB_1[1]=3
MD24120 ; 3. channel axis becomes GEOAX Z
$MC_TRAFO_GEOAX_ASSIGN_TAB_1[2]=2
MD24900 $MC_TRANSMIT_ROT_AX_OFFSET_1=0 ; rotation position X-Y plane against
zero position of the rotary axis
MD24910 ; Rotary axes turns
$MC_TRANSMIT_ROT_SIGN_IS_PLUS_1=FALSE
MD24920 $MC_TRANSMIT_BASE_TOOL_1 [0]=0.0 ; tool center distance in X
MD24920 $MC_TRANSMIT_BASE_TOOL_1 [1]=0.0 ; tool center distance in Y
MD24920 $MC_TRANSMIT_BASE_TOOL_1 [2]=0.0 ; tool center distance in Z
; activation TRANSMIT
; Programming in X,Y,Z
; Return to rotational operation
TRAFOOF
See also
TRACYL (Page 420)
6.10.2 TRACYL
The following figure shows an example relating to the configuration of axes and shows the
sequence of main steps required to configure the axes up to activation by TRACYL.
; General axis configuration for rotation

MD20060 $MC_AXCONF_GEOAX_NAME_TAB[1]="Y" ; Geometry axis
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[0] = 1 ; X as channel axis 1
Extended Functions
6.10 Examples
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[1]="YC"
MD20070 $MC_AXCONF_MACHAX_USED[0] = 2 ; X as machine axis 2
MD20070 $MC_AXCONF_MACHAX_USED[1] = 3 ; Y as machine axis 3
MD20070 $MC_AXCONF_MACHAX_USED[2] = 4 ; Z as machine axis 4
MD20070 $MC_AXCONF_MACHAX_USED[3] = 1 ; C as machine axis 1
MD20070 $MC_AXCONF_MACHAX_USED[4] = 5 ; AS as machine axis 5
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[AX3]= 0 ; Y is no spindle
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[0]="CM" ; 1. machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[1]="XM" ; 2. machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[2]="YM" ; 3. machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[3]="ZM" ; 4. machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[4]="ASM" ; 5. machine axis
; prepare for TRACYL (as first and only transformation)

MD24100 $MC_TRAFO_TYPE_1 = 513 ; Transformation TRACYL with groove wall
offset
MD24110 $MC_TRAFO_AXES_IN_1[0] = 1 ; channel axis radial to rotary axis
MD24110 $MC_TRAFO_AXES_IN_1[1] = 4 ; Channel axis in generated cylinder surface
perpendicular to rotary axis
MD24110 $MC_TRAFO_AXES_IN_1[2] = 3 ; channel axis parallel to rotary axis
MD24110 $MC_TRAFO_AXES_IN_1[3] = 2 ; Channel axis special axis to index [0]
MD24120 ; 1. channel axis becomes GEOAX X
$MC_TRAFO_GEOAX_ASSIGN_TAB_1 [0] = 1
MD24120 ; 2. channel axis becomes GEOAX Y
MD24120 ; 3. channel axis becomes GEOAX Z
MD24800 $MC_TRACYL_ROT_AX_OFFSET_1 ; rotation position X-Y plane against zero
=0 position of the rotary axis
Extended Functions
6.10 Examples
MD24810 ; Rotary axes turns

$MC_TRACYL_ROT_SIGN_IS_PLUS_1 =
FALSE
MD24820 $MC_TRACYL_BASE_TOOL_1 [0] = ; tool center distance in X
0.0
MD24820 $MC_TRACYL_BASE_TOOL_1 [1] = ; tool center distance in Y
0.0
MD24820 $MC_TRACYL_BASE_TOOL_1 [2] = ; tool center distance in Z
0.0
; activation TRACYL(40.0)
; Programming in Y and Z, see the following example
; Return to rotational operation
TRAFOOF
Programming with groove wall offset

(TRAFO_TYPE_n=513)
Contour
It is possible to produce a groove which is wider than the tool by using address OFFN to
program the compensation direction (G41, G42) in relation to the programmed reference
contour and the distance of the groove side wall from the reference contour (see following
figure).
Extended Functions
6.10 Examples
Tool radius
The tool radius is automatically taken into account with respect to the groove side wall (see
simplified figure). The full functionality of the plane tool radius compensation is available
(steady transition at outer and inner corners as well as solution of bottleneck problems).
=
1
1
2))1 1
1
1
3DWK,
3URJUDPPHGSDWK
3DWK,,
1
1
<
Figure 6-30 Groove with groove wall offset, cylinder coordinates
Example program that which guides the tool after transformation selection on path I via path
II back to the starting position

N1 SPOS=0; ; Transfer the spindle to rotary axis
operation
N5 G0 X25 Y0 Z105 CC=200 F5000 G64 ; Positioning of the machine above
groove center
N10 TRACYL(40.) ; Transformation selection with
reference diameter: 40 mm
N20 G19 G90 ; Machining plane is cylinder surface
N30 T1 D1 ; Tool selection, can also be before
TRACY (..)
N30 T1 D1 ; Infeed tool to groove base
N50 OFFN=12 ; Determine groove wall distance; it
does need not to be in its own line
Extended Functions
6.10 Examples

; Approach of groove wall
N60 G1 Z100 G42 ; TRC selection to approach groove wall
Machining groove sector path I
N70 G1 Z50 ; Groove part parallel to the cylinder
plane
N80 G1 Y10 ; Groove part parallel to the
circumference
; Approaching groove wall for path II
N90 OFFN=4 G42 ; Specify groove wall distance and TRC
selection to approach the groove wall
; Machining groove sector path II
N100 G1 Y70 ; Corresponds to CC=200 degrees
N110 G1 Z100 ; Revert to initial value
;Retract from groove wall
N120 G1 Z105 G40 ; TRC deselection to retract from the
groove wall
N130 G0 X25 ; Retract from the groove
N140 TRAFOOF N150 G0 X25 Y0 Z105 CC=200 D0 ; Return to the starting point and
deselect the tool offset
Programming without groove wall offset

TRACYL without groove wall offset with supplementary linear axis (TRAFO_TYPE_n = 514)
; For the following part program the following machine data settings are a prerequisite:
MD20070 $MC_AXCONF_MACHAX_USED[0]=1 ; X as machine axis 1
MD20070 $MC_AXCONF_MACHAX_USED[1] = 2 ; Y as machine axis 2
MD20070 $MC_AXCONF_MACHAX_USED[3] = 4 ; C as machine axis 4
MD20070 $MC_AXCONF_CHANAX_NAME_TAB[1] = "Y2"
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 [0] = 1 ; X as channel axis 1
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 [1] = 2 ; Y no channel axis
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[2]=3 ; Z as channel axis 2
MD24100 $MC_TRAFO_TYPE_1 = 514 ; TRACYL without groove wall
offset only with tool length offset
MD24110 $MC_TRAFO_AXES_IN_1[0] = 1 ; channel axis radial to rotary
axis
MD24110 $MC_TRAFO_AXES_IN_1[1] = 4 ; Channel axis in cylinder
surface
; perpendicular to rotary axis
MD24110 $MC_TRAFO_AXES_IN_1[2] = 3 ; channel axis parallel to rotary
axis
Extended Functions
6.10 Examples
MD24110 $MC_TRAFO_AXES_IN_1[3] = 2 ; Channel axis special axis to

index [0]
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 [0] = 1 ; 1. channel axis becomes
GEOAX X
GEOAX Y
GEOAX Z
MD24808 $MC_TRACYL DEFAULT MODE_1 =0 ; or not set at all
Tool data:
$TC_DP1[1,1]=120 ; Tool type shaft miller

$TC_DP2[1,1] = 0
$TC_DP3[1,1]=0 ; Length offset vector
$TC_DP4[1,1]=25
$TC_DP5[1.1] =5
$TC_DP6[1.1] =4 ; Radius, tool radius
Part program:

N1001 T1 D1 G54 G19 G90 F5000 G64 ; Selection of the 1st TRACYL without
N1005 G0 X25 Y0 Z105 A=200 groove wall offset
N1010 TRACYL(40.) ; Transformation selection

N1040 G1 X20
N1060 G1 Z100
N1070 G1 Z50
N1080 G1 Y10
N1140 TROFOOF
N1150 G0 X25 Y0 Z105 A=200 ; Selection of the 1st TRACYL with
groove wall offset
N2010 G0 TRACYL(40.,1,1) ; TRACYL (40., ,1) would also be
possible
N2040 G1 X20
N2060 G1 Z100
N2070 G1 Z50
N2080 G1 Y10
N2140 TROFOOF
Extended Functions
6.10 Examples
6.10.3 TRAANG
For the configuration shown in Figure "Groove with Groove Wall Offset, Cylinder
Coordinates", an example relating to the configuration of axes which shows the sequence of
main steps required to configure the axes up to activation by TRAANG is shown.
; General axis configuration for grinding

MD20060 $MC_AXCONF_GEOAX_NAME_TAB[1] = " " ; Geometry axis
MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[0] = 0 ; X no channel axis
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[0] = "Z"
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[1] = "C"
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[2] = "AS1"
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[3] = "MU"
MD20070 $MC_AXCONF_MACHAX_USED[1]=1 ; C as machine axis 1
MD20070 $MC_AXCONF_MACHAX_USED[2] = 4 ; AS as machine axis 4
MD20070 $MC_AXCONF_MACHAX_USED[3] = 2 ; MU as machine axis 2
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[0]= "C1" ; 1. Machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[1]= "MU" ; 2. Machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[2]= "MZ" ; 3. Machine axis
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[3]="AS1" ; 4. Machine axis
; prepare for TRAANG (as first and only transformation)

MD24100 $MC_TRAFO_TYPE_1 = 1024 ; Transformation TRAANG
MD24110 $MC_TRAFO_AXES_IN_1[0]=4 ; Channel axis inclined axis
MD24110 $MC_TRAFO_AXES_IN_1[1]=1 ; channel axis parallel to axis Z
MD24110 $MC_TRAFO_AXES_IN_1[2] = 0 ; Channel axis not active
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]=4 ; X 1st channel axis
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 [1] = 0 ; Y 2nd channel axis
MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 [2] = 1 ; Z 3rd channel axis
Extended Functions
6.10 Examples
MD24700 $MC_TRAANG_ANGLE_1 = 30. ; Angle of inclined axis

MD24710 $MC_TRAANG_BASE_TOOL_1 [0] = 0 ; tool center distance in X
MD24710 $MC_TRAANG_BASE_TOOL_1 [1] = 0 ; tool center distance in Y
MD24710 $MC_TRAANG_BASE_TOOL_1 [2] = 0 ; tool center distance in Z
TRAANG ; activation
; Programming in X,Y,Z
TRAFOOF ; Return to rotational operation
Examples
The following section determines:
The general channel configuration
Single transformations
Chained transformations consisting of previously defined single transformations
Activation of single transformations
Activation of chained transformations
The examples include the following transformations:
5-axis transformation with rotatable tool and axis sequence AB (trafo type 16)
Transmit (trafo type 256)
Inclined axis (trafo type 1024)
Chaining of the 1st and 3rd transformation (trafo type 8192)
Chaining of the 2nd and 3rd transformation (trafo type 8192)
General channel configuration
CHANDATA(1) ; Channel data in channel 1

MD20070 $MC_AXCONF_MACHAX_USED[0]=1
MD20070 $MC_AXCONF_MACHAX_USED[2] = 3
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[3]="A"
Extended Functions
6.10 Examples
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[4]="B"
MD20080 $MC_AXCONF_CHANAX_NAME_TAB[5] = "C"
MD36902 $MA_IS_ROT_AX[ AX4 ] = TRUE
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[AX5]= 0
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX[AX7] = 1
MD35000 $MA_ROT_IS_MODULO[AX7] = TRUE
Single transformations
; 1. TRAORI
MD24470 $MC_TRAFO_TYPE_1= 16 ; TRAORI: A-B kinematics
MD24120$MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]=1
MD24550$MC_TRAFO5_BASE_TOOL_1[0]=0
; 2. TRANSMIT
MD24200 $MC_TRAFO_TYPE_2 = 256 ; TRANSMIT
Extended Functions
6.10 Examples
; 3. TRAANG
MD24300 $MC_TRAFO_TYPE_3 = 1024 ; TRAANG
MD24700 $MC_TRAANG_ANGLE_1 = 45.
MD24710 $MC_TRAANG_BASE_TOOL_1 [0] = 0.0
Chained transformations
; 4. TRACON (Chaining TRAORI/TRAANG)

; 5. TRACON (Chaining TRANSMIT/TRAANG)
Extended Functions
6.10 Examples
Part program (extracts)

Example of an NC program which uses the set transformations:

; Call single transformations
; Tool specification
$TC_DP1[1,1]=120 ; Tool type
$TC_DP3[1,1] = 10 ; Tool length
n2 x0 y0 z0 a0 b0 f20000 t1 d1n4 x20
n30 TRANSMIT ; Switch on TRANSMIT
n40 x0 y20
n50 x-20 y0
n60 x0 y-20
n70 x20 y0
n80 TRAFOOF ; Switch off TRANSMIT
n130 TRACYL(45.) ; Activate inclined axis
transformation, parameters: Angle 45
n140 x0 y0 z20
n150 x-20 z0
n160 x0 z-20
n170 x20 z0
Note
The above examples assume that the angle of the "inclined axis" can be set on the machine
and is set to 0 when the single transformation is activated.

; 1. Activate chained transformations
; TRAORI + TRAANG
n230 TRACON(1, 45.) ; 1. of the 2 chained transformations
to be switched on
; The previously active transformation
TRAANG is automatically deselected
; The parameter for the inclined axis
is 45
n240 x10 y0 z0 a3=-1 C3 =1 oriwks
n250 x10 y20 b3 = 1 c3 = 1
Extended Functions
6.10 Examples

; 2. Activate chained transformations
; TRANSMIT + TRAANG
n330 TRACON(2, 40.) ; 2. activate chained transformation
; The parameter for the inclined axis
is 40
n335 x20 y0 z0
n340 x0 y20 z10
n350 x-20 y0 z0
n360 x0 y-20 z0
n370 x20 y0 z0
n380 TRAFOOF 2. deactivate chained transformation
n1000 M30
6.10.5 Activating transformation MD via a part program

It would be permissible in the following example to reconfigure (write) a machine data
affecting the second transformation (e.g. MD24650 $MC_TRAFO5_BASE_TOOL_2[2]) in
block N90, since writing a machine data alone does not activate it. However, if the program
remained otherwise unchanged, an alarm would occur in block N130, because an attempt
would then be made to modify an active transformation.
Example program:

N40 TRAORI(2) ; Select 2nd orientation transformation
N50 X0 Y0 Z0 F20000 T1 T1
N60 A50 B50
N70 A0 B0
N80 X10
N90 $MC_TRAFO5_BASE_TOOL_1[2] = 50 ; Overwrite a machine data item of the
1st orientation transformation
N100 A20
N110 X20
N120 X0
N130 NEWCONF ; Accept new machine data
N140 TRAORI(1) ; Selection of the 1st orientation
transformation MD is effective
N150 G19 X0 Y0 Z0
N160 A50 B50
N170 A0 B0
N180 TRAFOOF
N190 M30
Extended Functions
6.10 Examples
6.10.6 Axis positions in the transformation chain

Two chained transformations are configured in the following example, and the system
variables for determining the axis positions in the synchronous action are read cyclically in
the part program.

[ ;0

\ <0
75$160,7 75$$1*

] =0

\ &

[

\ 75$&</ 75$$1*

]

\
Machine data
CHANDATA(1)
MD24100 $MC_TRAFO_TYPE_1=256 ; TRANSMIT

MD24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1 [0] = 2
MD24200 $MC_TRAFO_TYPE_2=512 ; TRACYL

Extended Functions
6.10 Examples
MD24300 $MC_TRAFO_TYPE_3=1024 ; TRAANG

MD24700 $MC_TRAANG_ANGLE_1 = 45.
1st TRANSMIT / TRAANG chaining

MD24400 $MC_TRAFO_TYPE_4=8192 ; TRACON (1)
2nd TRACYL / TRAANG chaining

MD24430 $MC_TRAFO_TYPE_5=8192 ; TRACON (2)
MD24996 $MC_TRACON_CHAIN_2[2]=0
MD24996 $MC_TRACON_CHAIN_2[3]=0
Extended Functions
6.10 Examples
M17
Part program

N10 $TC_DP1[1,1]=120
N20 $TC_DP3[1,1]= 20
N30 $TC_DP4[1,1]=0
N40 $TC_DP5[1,1]=0
N50
N60 X0 Y0 Z0 F20000 T1 D1
N70
N80 ; cyclical reading of the variables in the synchronous action
N90 ID=1 WHENEVER TRUE DO $R0=$AA_ITR[X,0] $R1=$AA_ITR[X,1] $R2=$AA_ITR[X,2]
N100 ID=2 WHENEVER TRUE DO $R3=$AA_IBC[X] $R4=$AA_IBC[Y] $R5=$AA_IBC[Z]
N110 ID=3 WHENEVER TRUE DO $R6=$VA_IW[X]-$AA_IW[X]
N120 ID=4 WHENEVER TRUE DO $R7=$VA_IB[X]-$AA_IB[X]
N130 ID=5 WHENEVER TRUE DO $R8=$VA_IBC[X]-$AA_IBC[X]
N140 ID=6 WHENEVER TRUE DO $R9=$VA_ITR[X,1]-$AA_ITR[X,1]
N150
N160 ; 1. TRANSMIT / TRAANG chaining
N170 TRACON(1,)
N180 X20 Y0 Z0
N190 X0 Y20 Z10
N200 X-20 Y0 Z0
N210 X0 Y-20 Z0
N220 X20 Y0 Z0
N230 TRAFOOF
N240
N250 ; 2. TRACYL/ TRAANG chaining
N260 TRACON (2, 40.)
N270 X20 Y0 Z0
N280 X0 Y20 Z10
N290 X-20 Y0 Z0
N300 X0 Y-20 Z0
N310 X20 Y0 Z0
N320 TRAFOOF
N330
N340 M30
Extended Functions
6.11 Data lists
6.11 Data lists
6.11.1 Machine data
6.11.1.1 TRANSMIT
Channelspecific machine data

20110 RESET_MODE_MASK Definition of control basic setting after run-up and
RESET/part program end
20140 TRAFO_RESET_VALUE Basic transformation position
22534 TRAFO_CHANGE_M_CODE M code for transformation changeover
24100 TRAFO_TYPE_1 Definition of the 1st transformation in channel
24110 TRAFO_AXES_IN_1 Axis assignment for the 1st transformation
24120 TRAFO_GEOAX_ASSIGN_TAB_1 Geo-axis assignment for 1st transformation
24200 TRAFO_TYPE_2 Definition of the 2nd transformation in channel
24210 TRAFO_AXES_IN_2 Axis assignment for the 2nd transformation
24220 TRAFO_GEOAX_ASSIGN_TAB_2 Geo-axis assignment for 2nd transformation
24300 TRAFO_TYPE_3 Definition of the 3rd transformation in channel
24310 TRAFO_AXES_IN_3 Axis assignment for the 3rd transformation
24320 TRAFO_GEOAX_ASSIGN_TAB_3 Geo-axis assignment for 3rd transformation
24400 TRAFO_TYPE_4 Definition of the 4th transformation in channel
24410 TRAFO_AXES_IN_4 Axis assignment for the 4th transformation
24420 TRAFO_GEOAX_ASSIGN_TAB_4 Geo-axis assignment for 4th transformation
24900 TRANSMIT_ROT_AX_OFFSET_1 Deviation of rotary axis from zero position in degrees (1st
TRANSMIT)
Extended Functions
6.11 Data lists

24910 TRANSMIT_ROT_SIGN_IS_PLUS_1 Sign of rotary axis for TRANSMIT (1st TRANSMIT)
24911 TRANSMIT_POLE_SIDE_FIX_1 Limitation of working range in front of/behind pole, 1st
transformation
24920 TRANSMIT_BASE_TOOL_1 Distance of tool zero point from origin of geo-axes (1st
TRANSMIT)
24950 TRANSMIT_ROT_AX_OFFSET_2 Deviation of rotary axis from zero position in degrees (2nd
TRANSMIT)
24960 TRANSMIT_ROT_SIGN_IS_PLUS_2 Sign of rotary axis for TRANSMIT (2nd TRANSMIT)
24961 TRANSMIT_POLE_SIDE_FIX_2 Limitation of working range in front of/behind pole, 2nd
transformation
24970 TRANSMIT_BASE_TOOL_2 Distance of tool zero point from origin of geo-axes (2nd
TRANSMIT)
6.11.1.2 TRACYL

20144 TRAFO_MODE_MASK Selection of the kinematic transformation function
24130 TRAFO_INCLUDES_TOOL_1 Tool handling with active transformation 1.
Extended Functions
6.11 Data lists

24444 TRAFO_GEOAX_ASSIGN_TAB_6 Assignment geometry axes for 6th transformation
24800 TRACYL_ROT_AX_OFFSET_1 Deviation of rotary axis from zero position in degrees (1st
TRACYL)
24808 TRACYL_DEFAULT_MODE_1 Selection of TRACYL mode (1st TRACYL)
24810 TRACYL_ROT_SIGN_IS_PLUS_1 Sign of rotary axis for TRACYL (1st TRACYL)
24820 TRACYL_BASE_TOOL_1 Distance of tool zero point from origin of geo-axes (1st
TRACYL)
24850 TRACYL_ROT_AX_OFFSET_2 Deviation of rotary axis from zero position in degrees (2nd
TRACYL)
24858 TRACYL_DEFAULT_MODE_2 Selection of TRACYL mode (2nd TRACYL)
24860 TRACYL_ROT_SIGN_IS_PLUS_2 Sign of rotary axis for TRACYL (2nd TRACYL)
24870 TRACYL_BASE_TOOL_2 Distance of tool zero point from origin of geo-axes (2nd
TRACYL)
Extended Functions
6.11 Data lists
6.11.1.3 TRAANG

20144 RAFO_MODE_MASK Selection of the kinematic transformation function
24700 TRAANG_ANGLE_1 Angle of inclined axis in degrees (1st TRAANG)
24710 TRAANG_BASE_TOOL_1 Distance of tool zero point from origin of geometry axes (1st
TRAANG)
24720 TRAANG_PARALLEL_VELO_RES_1 Velocity reserve of parallel axis for compensatory motion
(1st TRAANG)
24721 TRAANG_PARALLEL_VELO_RES_2 Velocity reserve of parallel axis for compensatory motion
(2nd TRAANG)
24750 TRAANG_ANGLE_2 Angle of inclined axis in degrees (2nd TRAANG)
Extended Functions
6.11 Data lists

24760 TRAANG_BASE_TOOL_2 Distance of tool zero point from origin of geometry axes (2nd
TRAANG)
24770 TRAANG_PARALLEL_ACCEL_RES_1 Axis acceleration reserve of parallel axis for compensatory
motion (1st TRAANG)
24771 TRAANG_PARALLEL_ACCEL_RES_2 Axis acceleration reserve of parallel axis for compensatory
motion (2nd TRAANG)
6.11.1.4 Chained transformations

24995 TRACON_CHAIN_1 Transformation chain of the first chained transformation
24996 TRACON_CHAIN_2 Transformation chain of the second chained transformation
24997 TRACON_CHAIN_3 Transformation chain of the third chained transformation
24998 TRACON_CHAIN_4 Transformation chain of the fourth chained transformation
6.11.1.5 Non transformation-specific machine data

21110 X_AXIS_IN_OLD_X_Z_PLANE Coordinate system for automatic Frame definition
21090 MAX_LEAD_ANGLE Maximum permissible lead angle for orientation
programming
21092 MAX_TILT_ANGLE Maximum permissible side angle for orientation
programming
21100 ORIENTATION_IS_EULER Angle definition for orientation programming
6.11.2 Signals

Transformation active DB21, ... .DBX33.6 DB3300.DBX1.6
Extended Functions
6.11 Data lists
Extended Functions
M5: Measurement 7
Channel-specific measuring
The trigger event programmed for channel-specific measuring in a part program block
initiates the measuring operation and specifies the measurement method used for the
measurement. The instructions apply to all axes programmed in this particular block.
Axial measurement
In the case of axial measuring, a measurement can be made from the part program and also
from synchronized actions. A measurement method, the encoder and the trigger events are
programmed. Whereby the trigger events are formed from the probe (1 and 2) and the
trigger criterion (rising/falling signal edge). Depending on the measuring task, several
measured values per measurement and trigger event can be recorded.
Preset actual value memory and scratching

The preset actual value memory is initiated by means of an HMI operator action. The
calculated frame can be written to system frame $P_SETFRAME. The setpoint position of an
axis in the WCS can be altered when the actual value memory is preset.
The calculation is performed in the NC when a PI service is activated via
HMI operator action or a
Part program command from the measuring cycles.
The term scratching refers to both the workpiece measurement and the tool measurement.
The measurements can be initiated via the
HMI operator action or via
Measuring cycles.
Communication with the NC takes place via predefined system variables.
Extended Functions
M5: Measurement
7.2 Hardware requirements
Workpiece and tool measurement

The position of the workpiece can be measured in relation to an edge, a corner or a hole.
To determine the zero position of the workpiece (workpiece zero W) or a hole, setpoint
positions can be added to the measured positions in the workpiece coordinate system. The
resulting offsets can be entered in a selected frame.
In the case of tool measurement, the control calculates the distance between the tool tip and
the tool carrier reference point T from the tool length specified by the user.
Measuring cycles
A description of how to handle measuring cycles can be found in:
Literature:
Programming Manual Measuring cycles
7.2.1 Probes that can be used
Overview
A switching probe that supplies a constant bounce-free signal on deflection must be used for
the "Measuring" function in SINUMERIK controls. Probes that supply only one pulse for
deflection are not suitable.
Probe types
The probe types listed below differ depending on the number of possible deflection
directions:
Multidirectional probe (1)
Bidirectional probe (2)
Monodirectional probe (3)

Extended Functions
M5: Measurement
Probe types
Multidirectional probe (3D)

Multidirectional probes can be used unconditionally for measuring tool and workpiece
dimensions.
Bidirectional probe
Bidirectional probes are treated like monodirectional probes for the workpiece measurement
in milling and machining centers. Bidirectional probes for the workpiece measurement can
be used for turning machines.
Monodirectional probe
Monodirectional probes can be used for workpiece measurement on milling machines and
machining centers with only slight limitations.
Spindle position and monodirectional probe

The use of monodirectional probes in milling machines and machining centers requires that
the spindle can be positioned with the SPOS function and the switching signal of the probe
transferred over 360.
The probe must be mechanically aligned in the spindle to permit measurements in the
following directions at the 0 spindle position:
Plane Measurement direction

G17 (X-Y) Positive X direction
G18 (Z-X) Positive Z direction
G19 (Y-Z) Positive Y direction
Note
The complete measurement takes longer because the spindle needs to be positioned
several times with SPOS during the measuring cycle.
Extended Functions
M5: Measurement
7.3 Channel-specific measuring
7.3.1 Measurement
Activation
The measurement is activated from the part program. A trigger event and a measuring
method are programmed.
A distinction is made between two measuring methods:
MEAS: Measurement with deletion of distance-to-go
Example:
N10 G01 F300 X300 Z200 MEAS=-2
Trigger event is the falling edge (-) of the second probe (2).
MEAW: Measurement without deletion of distance-to-go
Example:
N20 G01 F300 X300 Y100 MEAW=1
Trigger event is the rising edge of the first probe (1).
The measuring job is aborted with RESET or when the program advances to a new block.
Note
If a geometry axis is programmed in a measuring block, the measured values are stored for
all current geometry axes.
If an axis participating in a transformation is programmed in a measurement block, the
measured values for all axes participating in this transformation are recorded.
Probe status
It is possible to scan the probe status directly in the part program and in synchronized
actions.
$A_PROBE[n] where n= probe
$A_PROBE[n]==1: Probe deflected
$A_PROBE[n]==0: Probe not deflected
Extended Functions
M5: Measurement
7.3.2 Measurement results
Reading measurement results

The results of the measurement commands are stored in system data of the NCK and can
be read via system variables in the part program.
System variable $AC_MEA[No]
Query measurement job status signal.
[No] stands for probe (1 or 2)
The variable is deleted at the beginning of a measurement. The variable is set as soon as
the probe fulfills the activation criterion (rising or falling edge). Execution of the
measurement job can thus be checked in the part program.
System variable $AA_MM[axis]
Access to measured value in the machine coordinate system (MCS)
Read in part program and in synchronized actions.
[Axis] stands for the name of the measurement axis (X, Y, ...).
System variable $AA_MW[axis]
Access to measured value in the workpiece coordinate system.
PLC service display

The functional test for the probe is performed using an NC program.
The measuring signal can be checked at the end of the program in the diagnostic menu
"PLC status".
Table 7- 1 Status display for measurement signal
Status display
Probe 1 deflected DB10, ...DBX107.0
Probe 2 deflected DB10, ...DBX107.1
The current measuring status of the axis is displayed by means of the interface signal DB31,
... DBX62.3.
Bit 3=1: Measurement
active Bit 3=0: Measurement not active
This signal can be displayed for all measurement functions and also be read in synchronized
actions with
system variable $AA_MEAACT[axis].
References:
Extended Functions
M5: Measurement
7.4 Axial measurement
7.4.1 Measurement
Activation
Axial measurement can be programmed with and without deletion of distance-to-go. The
activation of the measuring is carried out from the part program or a synchronized action.
The measuring method and up to four trigger events are programmed. The measuring mode
specifies the chronological or programmed sequence of the trigger events. For the
continuous measurement, the number of the circular buffer (FIFO) is programmed.
A distinction is made between three measuring methods:
MEASA: Measurement with deletion of distance-to-go
Example:
N10 MEASA[X]=(1,1,-1) G01 X100 F100
Measuring in mode 1 with active measuring system. Trigger events are the rising and
falling edge of the first probe (1) on the travel path to X=100.
Note
MEASA cannot be programmed in synchronized actions.
MEAWA: Measurement without deletion of distance-to-go

Example:
N20 MEAWA[X]=(1,-1,1,-2,2) G01 X100 F100
Measuring in mode 1 with active measuring system. Trigger events are the falling and
rising edge of the first probe (1) and of the second probe (2) on the travel path to X=100.
MEAC (option): Continuous measurement without deletion of distance-to-go
Example:
N30 MEAC[X]=(1,1,-2,2) G01 X100 F100
Measuring in mode 1 with active measuring system. Save the measured values under the
first FIFO (1). Trigger events are the falling and rising edge of the second probe (2) on
the travel path to X=100.
The measuring job is aborted with RESET or when the program advances to a new block.
Note
MEASA and MEAWA can be programmed in a block. If MEASA/MEAWA are programmed in
the same block as MEAS/MEAW, an error message will be output.
Extended Functions
M5: Measurement
Measuring mode
The measuring mode specifies whether trigger events must be activated in parallel or
sequentially in ascending sequence and defines the number of measurements to be taken.
Units decade (measuring mode)
0 = abort measurement job (e.g. for synchronized actions)
1 = up to four different trigger events that can be activated at the same time.
2 = up to four trigger events can be activated in succession.
Error output if the first trigger event is already present
3 = up to four trigger events can be activated in succession.
NO error output if the first trigger event is already present
Tens decade (measuring system)
0/not set = use active measuring system
1 = first measuring system
2 = second measuring system (if available, otherwise the first measuring system is used.
No error message is output).
3 = first and second measuring system
Note
If the measuring job is performed with two measuring systems, a maximum of two trigger
events can be programmed. The measured values of both measuring systems are
acquired for each of the two trigger events.
Mode 3 is not supported by MEAC.
Trigger event
A trigger event comprises the number of the probe and the trigger criterion (rising or falling
edge) of the measuring signal.
1 = rising edge of probe 1
-1 = falling edge of probe 1
2 = rising edge of probe 2
-2 = falling edge of probe 2
If the measuring operation is performed with two measuring systems, a maximum of two
trigger events per probe can be programmed (rising or falling edge). The measured values of
both probes are acquired for each of the two trigger events. The default PROFIBUS telegram
391 setting means one measured value per trigger event and position controller cycle is
possible.
For MEAC, the number of measured values per trigger event can be increased with
PROFIBUS telegram 395 to eight measured values for rising edge and eight measured
values for falling edge of each measuring input and position control cycle. This allows higher
feed rates or speeds to be implemented compared with PROFIBUS telegram 391.
For further information concerning the telegram selection, see Section "Telegram selection
(Page 449)".
Extended Functions
M5: Measurement
FIFO variables
The axial measured values are available in the machine coordinate system (MCS). They are
stored in the circular buffer (FIFO) specified by MEAC. The measured values are entered in
FIFO variables in the FIFO using the circular principle, e.g. $AC_FIFO1. When two probes
have been projected for the measurement, the measured values of the second probe are
saved separately in the subsequent FIFO.
The number of measured values is limited. The length of the FIFO can be configured in the
MD28264 LEN_AC_FIFO (length of the FIFO variables $AC_FIFO1 - $AC_FIFO10)
The values can be read from the FIFO both in the part program and from synchronized
actions.
The measurement remains active until:
MEAC[axis]=(0) is programmed
a FIFO is full
RESET is pressed or end of program M02/M30 is reached
References:
Function Manual, Synchronized Actions; Detailed Description,
Section: Parameters ($AC_FIFO)
Probe status
It is possible to scan the probe status directly in the part program and in synchronized
actions.
$A_PROBE[n] where n= probe
$A_PROBE[n]==1: Probe deflected
$A_PROBE[n]==0: Probe not deflected
Probe limitation
The probe limitation is available at the following system variables for PROFIBUS telegram
395:
$A_PROBE_LIMITED[n], where n = probe
$A_PROBE_LIMITED[n]==1: Probe limitation active
$A_PROBE_LIMITED[n]==0: Probe limitation inactive/reset
For additional information on system variables, see:
Reference:
Parameter Manual, System Variables
Extended Functions
M5: Measurement
7.4.2 Telegram selection
Telegram selection for the axial measurement with MEAC

By default, the axial measurement is implemented with PROFIBUS telegram 391.
PROFIBUS telegram 395 is used for measuring with several measured values per trigger
event and the position control cycle.
The telegram selection is made from the STEP 7 HW Config, in the "DP Slave Properties" >
"Configuration" dialog.
The following settings are also required:
Drive parameters:
CU: p0922 = 395; setting for the telegram selection
CU: p0684 = 16; setting of the measuring procedure
CU: p0680; configuration of the central probe terminal
PROFIBUS connection:
MD13211 $MN_MEAS_CENTRAL_SOURCE = 2 (telegram integration without
handshake)
7.4.3 Measurement results
Read measurement results of MEASA, MEAWA

The results of the measurement commands are stored in system data of the NCK and can
be read via system variables in the part program.
System variable $AC_MEA[No]
Query measurement job status signal.
[No] stands for probe (1 or 2)
The variable is deleted at the beginning of a measurement. The variable is set as soon as
the probe fulfills the activation criterion (rising or falling edge). Execution of the
measurement job can thus be checked in the part program.
System variable $AA_MM1[axis] to $AA_MM4[axis]
Access to the measured value of the trigger signal in the machine coordinate system.
System variable $AA_MW1[axis] to $AA_MW4[axis]
Access to the measured value of the trigger signal in the workpiece coordinate system.
Extended Functions
M5: Measurement
Two measuring systems

If the measuring job is performed with two measuring systems, a maximum of two trigger
events can be programmed. The measured values of both probes are acquired for each of
the two probes.
One trigger event
$AA_MM1[axis] = trigger event 1, measured value from encoder 1
Two trigger events
PLC service display

For further information about the functional test of the probe, see Section "Measurement
results (Page 445)".
Read measurement results of MEAC

All measurements are written to a previously defined FIFO variable. The possible number of
measured values is defined via the machine data (see Section "Measurement (Page 446)").
The correct operation is executed reliably for PROFIBUS telegram 391 for the ratios of
the IPO clock / position controller cycle 8:1.
The correct operation is executed reliably for PROFIBUS telegram 395 for the ratios of
the IPO clock / position controller cycle 4:1.
The contents of the FIFO memory can be read only once. When measurement results are
used more than once, the read-out values must be buffered in the user data.
Endless measuring
In order to implement endless measuring, FIFO values must be read cyclically from the part
program. The frequency with which the measured values are read from the FIFO memory
and processed must correspond to the writing frequency of the NC.
The number of valid entries is readable in a FIFO variable.
If measuring is to be terminated after reaching a defined number of measured values, the
measurement job must explicitly be deselected in the program.
Extended Functions
M5: Measurement
7.5 Setting zeros, workpiece measuring and tool measuring
7.5.1 Preset actual value memory and scratching
Preset actual value memory

Preset actual value memory is initiated by means of an HMI operator action or via measuring
cycles. The calculated frame can be written to system frame $P_SETFRAME. The setpoint
position of an axis in the WCS can be altered when the actual value memory is preset.
The calculation is performed in the NC when a PI service is activated via
HMI operator action or a
Part program command from the measuring cycles.
A tool and a plane can be selected as a basis for the calculation. The calculated frame is
entered in the result frame.
Scratching
The term scratching refers to both the workpiece and tool measurement. The position of the
workpiece can be measured in relation to an edge, a corner or a hole. To determine the zero
position of the workpiece or the hole, setpoint positions can be added to the measured
positions in the WCS. The resulting offsets can be entered in a selected frame. In the tool
measurement, the length or radius of a tool can be measured using a measured reference
part.
The measurements can be initiated via the
HMI operator action or via
Measuring cycles.
Communication with the NC takes place via predefined system variables. The calculation is
performed in the NCK when a PI service is activated via:
the HMI operator action
or through a part program command from the measuring cycles.
A tool and a plane can be selected as a basis for the calculation. The calculated frame is
entered in the result frame.
For more detailed information about channel-specific system frames, please see:
Parameter Manual, System Variables; list of system variables, Section: Frames
Function Manual, Basic Functions; Axes, Coordinate Systems, Frames (K2),
Section: Frames of the frame chain
Additional references:
Programming Manual, Production Planning; Technology Cycles
, Section: Swiveling - CYCLE800
Extended Functions
M5: Measurement
7.5.2 Workpiece measuring
Workpiece measuring
For workpiece measurement, a probe is moved up to the clamped workpiece in the same
way as a tool. Due to the variety of different measuring types available, the most common
measurement jobs can be performed quite simply and easily on a turning or milling machine.
The position of the workpiece can be measured in relation to an edge, a corner or a hole.
To determine the zero position of the workpiece (workpiece zero W) or a hole, setpoint
positions can be added to the measured positions in the WCS. The resulting offsets can be
entered in a selected frame.
Variable interface
The variable interface comprises several system variables,
These are categorized as either:
Input values
Output values
Reference:
Parameter Manual, System Variables
Input values must be written by the HMI or the cycles. The output values result from the
calculations.
References:
Programming Manual, Measuring Cycles
7.5.2.1 Input values
Validity bits for the measurement types

To define which system variables are valid for the current measurement, each measuring
process must first declare all the variables as invalid. This is done with:
$AC_MEAS_VALID = 0.
Each input variable implicitly sets the corresponding bit in $AC_MEAS_VALID when writing
to the interface. If the validity bits are not reset, the values remain valid for the next
calculation.
Note
The interface is not reset in case of machine control table reset or after M30 (reset at
program end).
Extended Functions
M5: Measurement
Table 7- 2 Validity bits for the input values of the variables $AC_MEAS_VALID
Bit Input value Meaning

0 $AA_MEAS_POINT1[axis] 1. Measuring point for all channel axes
4 $AA_MEAS_SETPOINT[axis] Setpoint position of the edge, corner, hole
5 $AC_MEAS_WP_SETANGLE Setpoint workpiece position angle ; -90 < <
180
6 $AC_MEAS_CORNER_SETANGLE Setpoint angle of intersection of the corner 0
< < 180
7 $AC_MEAS_T_NUMBER Selected tool
7 $AC_MEAS_D_NUMBER Selected cutting edge
9 $AC_MEAS_DIR_APPROCH Approach direction for edge, groove, web and
tool measurement only
10 $AC_MEAS_ACT_PLANE Set working plane and infeed direction
11 $AC_MEAS_FRAME_SELECT Calculated frame in the specified frame
12 $AC_MEAS_TYPE Types of workpiece measurement
13 $AC_MEAS_FINE_TRANS Enter translational offsets
14 $AA_MEAS_SETANGEL[axis] Setpoint angle of an axis
15 $AA_MEAS_SCALEUNIT Unit of measurement for input and output
values
16 $AA_MEAS_TOOL_MASK Tool settings
17 $AA_MEAS_P1_COORD Coordinate system of 1st measuring point
18 $AA_MEAS_P2_COORD Coordinate system of 2nd measuring point
19 $AA_MEAS_P3_COORD Coordinate system of 3rd measuring point
20 $AA_MEAS_P4_COORD Coordinate system of 4th measuring point
21 $AA_MEAS_SET_COORD Coordinate system of setpoint
22 $AA_MEAS_CHSFR System frame mask
23 $AA_MEAS_NCBFR Mask for global basic frame
24 $AA_MEAS_CHBFR Mask for channel basic frames
25 $AA_MEAS_UIFR Settable frame from data management
26 $AA_MEAS_PFRAME Do not calculate programmable frames
27 $AC_MEAS_INPUT[n] Measuring input parameter with length n
Note
All axis actual values of the appropriate measuring point are invalidated by:
$AC_MEAS_LATCH = 0
Extended Functions
M5: Measurement
Measuring points
A maximum of four measuring points are available for all channel axes for measurement:
Type Input variable Meaning

REAL $AA_MEAS_POINT1[axis] 1. Measuring point for all channel axes
The measured points are normally available as actual values (= setpoint values) in WCS. A
measuring point is denoted as valid as soon as an axis value is described for it. Each
individual measuring point can be written or picked up.
A few measuring types also support measuring points lying in a different coordinates system
(BCS, MCS). The entry in which the coordinates system of the corresponding measuring
point was measured can be done via the following variables:
Type Input variable Meaning Values

INT $AA_MEAS_P1_COORD Coordinate system of 1st measuring point 0: WCS is the standard setting
INT $AA_MEAS_P2_COORD Coordinate system of 2nd measuring point 1: BCS
2: MCS
INT $AA_MEAS_P3_COORD Coordinate system of 3rd measuring point 3: ENS
INT $AA_MEAS_P4_COORD Coordinate system of 4th measuring point 4: WCS_REL
INT $AA_MEAS_SET_COORD Coordinate system of setpoint 5: ENS_REL
Actual values
The measuring points can be described for all the axes having the current axis actual values.
The positions are picked up with reference to the selected coordinates system. The positions
are attached in WCS if no coordinates system is specified. The following variable is used for
this purpose:
$AC_MEAS_LATCH[0..3]
The index varies from 0 to 3, corresponding to the 1st to 4th measuring point. Assigning the
value zero to the variable has the effect that all axis actual values of the corresponding
measuring point become invalid. Assigning the value 1 picks up all the axis actual values in
the corresponding measuring point. The variable is a write-only variable.
Individual axis actual values of a measuring point can be described with the following
variables:
Type System variable Meaning Values

REAL $AA_MEAS_P1_VALID[ax] 1. Pick up the measuring point of an axis 0: The measuring point of the axis is
REAL $AA_MEAS_P2_VALID[ax] 2. Pick up the measuring point of an axis invalid
REAL $AA_MEAS_P3_VALID[ax] 3. Pick up the measuring point of an axis 1: The measuring point of the axis is
determined
REAL $AA_MEAS_P4_VALID[ax] 4. Pick up the measuring point of an axis
The variables $AC_MEAS_LATCH[0..3] and $AA_MEAS_P[1..4]_VALID can be used

interactively. Allowance is made accordingly for the facing axis with diameter programming.
Extended Functions
M5: Measurement
Setpoints
The resultant frame is calculated so that the measurement complies with the setpoints
specified by the user.
Table 7- 3 Input values for the user setpoint values

REAL $AA_MEAS_SETPOINT[ax] Setpoint position of an axis
REAL $AA_MEAS_SETANGLE[ax] Setpoint angle of an axis
INT $AA_MEAS_SP_VALID[ax] 1: Setpoint position of axis is valid / 0: Invalid
REAL $AC_MEAS_WP_SETANGLE Rated workpiece position angle : -90 < <
180
REAL $AC_MEAS_CORNER_SETANGLE Setpoint cutting angle of corner: 0 < < 180
INT $AC_MEAS_DIR_APPROACH *) Approach direction:
0: +x, 1: -x, 2: +y, 3: -y, 4: +z, 5: -z
*) The approach direction is required only for the edge, groove, web and tool measurement.
The following measuring points are irrelevant and not evaluated:

On inputting the setpoint workpiece position angle : of the 2nd measuring point.
When inputting the setpoint angle of intersection : at the 4th measuring point.
Plane separation
Plane separation for defining the tool orientation. The active level is used for all calculations
if no level is specified.
Type System variable Values

INT $AC_MEAS_ACT_PLANE 0: G17 working plane x/y infeed direction z
1: G18 working plane z/x infeed direction y
2: G19 working plane y/z infeed direction x
Translational offsets
When measuring workpieces, translational offsets can be entered in the fine offset
component of the selected frame. Variable $AC_MEAS_FINE_TRANS is used for this
purpose.
Type System variable Values

INT $AC_MEAS_FINE_TRANS 0: Translational compensation is entered in the
coarse offset.
1: Translational compensation is entered in the
fine offset.
Extended Functions
M5: Measurement
The following is applicable if the variable $AC_MEAS_FINE_TRANS is not described:

The compensation value is entered in the coarse offset and transformed in the time
frame. There can also be a fine portion in the translation by virtue of the transformations.
If the following machine data is not preset to 1:
MD18600 $MN_MM_FRAME_FINE_TRANS
The compensation is always entered in the course offset.
Calculated frame
When a workpiece is measured, the calculated frame is entered in the specified frame.

INT $AC_MEAS_FRAME_SELECT Frame selection during tool measurement
The variable $AC_MEAS_FRAME_SELECT can assume the following values:
Value Meaning
0 $P_SETFRAME Active system frame
1 $P_PARTFRAME Active system frame
2 $P_EXTFRAME Active system frame
10..25 $P_CHBFRAME[0..15] Active channel-specific basic frames
50..65 $P_NCBFRAME[0..15] active NCU-global basic frames
100..199 $P_IFRAME The calculation is done using the active settable
frame, if the corresponding frame is selected. If
the selected frame is not active, the corresponding
data management frame is included in the
calculation.
500 $P_TOOLFRAME Active system frame
501 $P_WPFRAME Active system frame
502 $P_TRAFRAME Active system frame
503 $P_PFRAME Active current programmable frame
504 $P_CYCFRAME Active system frame
505 $P_RELFRAME (workpiece Active system frame
coordinate system)
506 $P_RELFRAME (SZS) Active system frame
1010..1025 $P_CHBFRAME[0..15] active channel specification Basic frames with
active G500
1050..1065 $P_NCBFRAME[0..15] active NCU-global Basic frames with active G500
2000 $P_SETFR System frame in data management
2001 $P_PARTFR System frame in data management
2002 $P_EXTFR System frame in data management
2010..2025 $P_CHBFR[0..15] Channel-specific basic frames in data
management
2050..2065 $P_NCBFR[0..15] NCU-global basic frame in data management
Extended Functions
M5: Measurement
Value Meaning
2100..2199 $P_UIFR[0..99] settable frame in data management
2500 $P_TOOLFR System frame in data management
2501 $P_WPFR System frame in data management
2502 $P_TRAFR System frame in data management
2504 $P_CYCFR System frame in data management
2505 $P_RELFR (workpiece System frame in data management
coordinate system)
2506 $P_RELFR (SZS) System frame in data management
3010..3025 $P_CHBFR[0..15] Channel-spec. Basic frames with active G500 in
data management
3050..3065 $P_NCBFR[0..15] NCU-global basic frames with active G500 in data
management
The MEASURE( ) function calculates frame $AC_MEAS_FRAME according to the specified

frame.
In the case of values
0 to 1065, the calculation is performed using the active frame.
2000 to 3065, the calculation is performed with reference to the selected frame in data
management. The frame selection in data management is not supported for measurement
types 14 and 15. A frame does not have to be active in order to select it in data
management. In this case, the calculation is performed as if the frame were active in the
chain.
The measuring point is transformed in the selected system and the selected frame is
determined using the entire frame including the selected frame. Preset actual value memory
is active only after compensation and activation of the frame.
In the case of values
With active G500 active (1010..1025, 1050..1065, 3010..3025, 3050..3065), the target frame
is calculated so that G500 must be active after the frame is selected so that the setpoint
position can be calculated.
Conversion into another coordinate system

If a position is to be converted to a position in another coordinate system, the following
variables can be used to specify the composition of the desired frame chain:

INT $AC_MEAS_CHSFR Selection of system frames Bit mask corresponding to MD28082
$MC_MM_SYSTEM_FRAME_MASK
INT $AC_MEAS_NCBFR Selection of global basic frames Bit mask (0 ... FFFF)
INT $AC_MEAS_CHBFR Selection of channel basic frames Bit mask (0 ... FFFF)
INT $AC_MEAS_UIFR Selection of settable frames 0 ... 99
INT $AC_MEAS_PFRAME Programmable frame 0: is included
1: is not included
Extended Functions
M5: Measurement
The data management frames are read and a new frame set up for the corresponding values
in the variables.
Note
If variables are not set, the active frames are retained.
Values should only be written to those variables whose data management frames are to be
included in the new frame chain. In the case of the basic frames, only all of the frames can
be exchanged, and not just a particular frame. Active changes via $P_NCBFRMASK and
$P_CHBFRMASK are ignored.
Array variable for workpiece and tool measurement

The following array variable of length n is used for further input parameters that are used in
the various measurement types

REAL $AC_MEAS_INPUT[n] Measurement input n = 0 ... 9
parameters
The control action of the measurement input parameters is described with the measuring
methods.
Selection of tool or cutting edge

The tool and edge number of the active tool must correspond to the selected tool. When T0,
D0 is selected, the active tool is calculated. If no tool is active, the tool selected by T, D is
calculated. No tool other than the selected tool may be active.

INT $AC_MEAS_T_NUMBER Selected tool
INT $AC_MEAS_D_NUMBER Selected cutting edge
Measurements with 3D probe

When measuring with the 3D probe, the radius of the tool is already compensated with
reference to the measuring point, and therefore the radius does not have to be included
when calculating the various measurement operations. This property can be defined by
means of the following variable:

INT $AC_MEAS_TOOL_MASK Tool position
Extended Functions
M5: Measurement
The variable $AC_MEAS_TOOL_SCREEN can assume the following values:
Value Meaning
0x0 All tool lengths are considered (default setting).
0x1 Tool radius is not included in the calculation
0x2 Tool position in x direction (G19)
0x4 Tool position in y direction (G18)
0x8 Tool position in y direction (G17)
0x10 Tool length is not included in the calculation
0x20 Length of the active tool is included in the coordinate transformation of a position.
0x40 Tool position in x direction.
0x80 Tool position in y direction.
0x100 Tool position in z direction.
0x200 Tool length differential values are included negatively.
Whether or not the radius of a milling tool is included in the calculation can be determined
from the tool position and approach direction. If the approach direction is not specified
explicitly, it is determined by the selected plane.
Plane Approach direction

G17 -z direction
G18 - y direction:
G19 - x direction
7.5.2.2 Measurement selection

The measurement is selected by means of the following variable:
Type System variable Description

INT $AC_MEAS_TYPE Measurement type selection
The variable $AC_MEAS_TYPE can assume the following values:
Value Description
0 Default
1 Edge_x Measuring the x edge
2 Edge_y Measuring the y edge
3 Edge_z Measuring the z edge
4 Corner_1 Measuring Corner 1
8 Hole Measuring a hole
Extended Functions
M5: Measurement
Value Description
9 Stud Measuring a shaft
10 * Tool length Measuring the tool length
11 * ToolDiameter Measuring the tool diameter
12 Slot Measuring a groove
13 Plate Measuring a web
14 Set_Pos Preset actual value for geometric and special axes
15 Set_AuxPos Preset actual value memory for special axes only
16 Edge_2P Measuring an inclined edge
17 Plane_Angles Angle of a plane
18 Plane_Normal Angle of a plane with setpoint input
19 Dimension_1 1-dimensional setpoint value
22 * ToolMagnifier ShopTurn: Measurement of tool lengths with zoom-in
function
23 * ToolMarkedPos ShopTurn: Measuring a tool length with marked position
24 Coordinate transformation Coordinate transformation of a position
25 Rectangle Measurement of a rectangle
26 Save Saving data management frames
27 Restore Restoring data management frames
28 Taper turning Additive rotation of the plane
* Types of workpiece measurement

The individual methods are listed under "Types of workpiece measurement" or "Types of tool
measurement"and explained in more detail using an appropriate programming example.
7.5.2.3 Output values
Calculation results
If a setpoint position has been specified, the resulting frame is entered in result frame
$AC_MEAS_FRAME. This frame can be read and written in the part program. The result
frame is calculated according to the selected frame.
If no frame has been selected, the result frame determines the final translation and rotation
in the WCS. This frame can be entered in the selected frame using the PI service
_N_SETUDT and parameter type no. 7. Once it has been entered, the result frame is
deleted.
Table 7- 4 Output values of calculation results

FRAME $AC_MEAS_FRAME Result frame
REAL $AC_MEAS_WP_ANGLE Calculated workpiece position angle
Extended Functions
M5: Measurement

REAL $AC_MEAS_CORNER_ANGLE Calculated angle of intersection
REAL $AC_MEAS_DIAMETER Calculated diameter
REAL $AC_MEAS_TOOL_LENGTH Calculated tool length
REAL $AC_MEAS_RESULTS[10] Calculation results (depending on
$AC_MEAS_TYPE)
7.5.2.4 Calculation method
Activating the calculation

The calculation is activated by an HMI operator action with PI service _N_SETUDT. This Pl
service can accept one of the following parameter types:
Type Meaning
1 Active tool offset
2 Active basic frames
3 Active settable frame
4 Global basic frames
5 Global settable frames
6 Calculate workpiece zero or tool lengths
7 Activate workpiece zero (write scratching)
8 Activate external work offset
9 Activate active tool carrier, TCOABS and PAROT
The change becomes apparent immediately in the reset state. In the stop state, the frame is
retracted at the next start.
Note
The PI service can be executed only in the reset and stop states. In the case of workpiece
measurement, the calculated frame is activated immediately with type no. 7. In the case of
tool measurement, the PI service must not be dispatched with type no. 7, since a zero point
does not have to be activated.
Activation in the Stop state

The new WCS positions are refreshed in the Stop state. With the continuation start on the
part program, the distance-to-go of the interrupted block is deleted. Traversal is made from
the current position to the end point of the next block.
Therefore, it is also possible in the Stop state to start a spindle in the MDA mode or in the
part program and set and scratch an actual value with M0. Another measurement can also
be performed.
Extended Functions
M5: Measurement
Measuring cycles
The calculation in the measuring cycles is performed according to the predefined function:
INT MEASURE( )
MEASURE() delivers a result frame that can be read via $AC_MEAS_FRAME:
The result is the translation and rotation from the setpoint values recalculated on the
selected frame.
The result frame is calculated as follows:
The concatenated total frame produces the concatenation of the total frame (prior to
measurement) with the calculated translation and rotation.
NOTICE
No preprocessing limitation
MEASURE() does not trigger any implicit block search stop. Because MEASURE( )
works with the frames of the preprocessing block, the user must decide whether a
preprocessing stop is required prior to the calculation.
Note
If no frame is selected, the calculated frame is not transformed, i.e. the translation and
rotation is determined on the basis of the specified setpoints and the calculated position
of the edge, corner, groove, etc. Where the function is used more than once, it is always
added to the result frame.
The result frame may need to be deleted beforehand.
Semaphore variable
The measurement variable occurs only once per channel. The measuring operation can be
initiated via an operator input in the stop and reset states. The operation can overlap with the
measuring cycles in the stop state. The following variable serves to protect against mutual
overwriting:
$AC_MEAS_SEMA (semaphore of measurement interface)
The semaphore variable $AC_MEAS_SEMA is
set to 1 at the beginning of the cycle and
reset to 0 again at the end of the cycle.
HMI does not use the measurement interface if the variable has the value 1.
Error messages
If the client does not log on, group error number 0xD003 is always generated. If a logon
takes place through DIAGN:errCodeSetNrGent or DIAGN:errCodeSetNrPi, then PI_SETUDT
provides the error code corresponding to the following syntax:
EX_ERR_PI_REJ_<return value>, e.g. EX_ERR_PI_REJ_ MEASNOTYPE
Extended Functions
M5: Measurement
The following return values are output via the pre-defined MEASURE() function:
Table 7- 5 Predefined error messages
No. Return values Meaning

0 MEAS_OK Correct calculation
1 MEAS_NO_TYPE Type not specified
2 MEAS_TOOL_ERROR Error determining the tool
3 MEAS_NO_POINT1 Measuring point 1 does not exist
7 MEAS_NO_SPECPOINT No reference point available
8 MEAS_NO_DIR No approach direction
9 MEAS_EQUAL_POINTS Measuring points are identical
10 MEAS_WRONG_ALPHA Alpha is wrong
11 MEAS_WRONG_PHI Phi is wrong
12 MEAS_WRONG_DIR Wrong approach direction
13 MEAS_NO_CROSSING Lines do not intersect
14 MEAS_NO_PLANE Planes do not exist
15 MEAS_WRONG_FRAME No frame or incorrect frame selected
16 MEAS_NO_MEMORY Insufficient memory available
17 MEAS_INTERNAL_ERROR Internal error
Tool measurement error

In the case of error code MEAS_TOOL_ERROR or EX_ERR_PI_REJ_MEASTOOLERROR,
the system stores a more detailed specification of the error with the following values in
output variable $AC_MEAS_TOOL_LENGTH:
Table 7- 6 Predefined error messages for MEAS_TOOL_ERROR
No. Return values Meaning

1 TOOL_NO_BLOCK No block available for the tool calculation
2 TOOL_WRONG_T_NUMBER Wrong T number
3 TOOL_WRONG_D_NUMBER Wrong D number
4 TOOL_EVAL_WRONG_TYPE The tool does not exist
5 TOOL_NO_TOOLCORR_BODY Memory problem
6 TOOL_DATA_READ_ERROR Error reading the tool data
7 TOOL_NO_TOOL_WITH_TRAFO No tool is selected with an active transformation
Extended Functions
M5: Measurement
7.5.2.5 Units of measurement and measurement variables for the calculation
INCH or METRIC unit of measurement

The following input and output variables are evaluated with inch or metric units of
measurement:
$AA_MEAS_POINT1[axis] Input variable for 1st measuring point

$AA_MEAS_POINT2[axis] Input variable for 2nd measuring point
$AA_MEAS_POINT3[axis] Input variable for 3rd measuring point
$AA_MEAS_POINT4[axis] Input variable for 4th measuring point
$AA_MEAS_SETPOINT[axis] Input variable for setpoint position
$AC_MEAS_DIAMETER Output variable for calculated diameter
$AC_MEAS_TOOL_LENGTH Output variable for calculated tool length
$AC_MEAS_RESULTS[n] Output variable for calculation results
The system of units in which the input and output values can be read or written can be set
via the input variable.
INT $AC_MEAS_SCALEUNIT Unit of measurement for input and output

variable
0: Unit of measurement with reference to active G codes G70/G700 in INCH
active G codes G71/G701 in METRIC
1: Unit of measurement corresponds to the configuration; the measurement system can
be set via OPI (standard setting)
The value 1 is always treated as the standard setting if the variable is not written.
Example:
The basic system is metric:

G70
$AC_MEAS_POINT1[x] = $AA_IW[x] ; $AA_IW[x] supplies the basic system
$AC_MEAS_POINT1[x] = 10 ; 10 mm
G71
$AC_MEAS_POINT1[x] = $AA_IW[x] ; $AA_IW[x] supplies the basic system
G700
$AC_MEAS_POINT1[x] = $AA_IW[x] ; $AA_IW[x] supplies inch value
$AC_MEAS_POINT1[x] = 10 ; 10 inch
G710
$AC_MEAS_POINT1[x] = $AA_IW[x] ; $AA_IW[x] supplies metric value
Extended Functions
M5: Measurement
Diameter programming
Diameter programming is set via machine data:
MD20100 $MC_DIAMETER_AX_DEF = "X" ; Transverse axis is x

MD20150 $MC_GCODE_RESET_VALUES[28] = 2 ; DIAMON
MD20360 $MC_TOOL_PARAMETER_DEF_MASK ; Tool length, frames and
= 'B1001010' ; Actual value in the diameter
The following is to be taken into account:
Axis positions in the MCS are not included as diameter value.
The calculated tool lengths and frame components do not depend on the active G code
DIAMON or DIAMOF.
The measured positions and setpoint positions are read and written depending on
DIAMON.
The translations in the frames are calculated as a diameter in the transverse axis.
Arithmetic and display precision

Position values in mm, inches or degrees are accurately calculated and displayed to six
decimal places.
7.5.2.6 Diagnostics
The following diagnostic options exists for the measurement interface:
If the file /_N_MPF_DIR/_N_MEAS_DUMP_MPF is available, a log is written in the file that
should enable the reproduction of the problem.
The logging is started by creating a blank file having the filename _N_MEAS_DUMP_MPF
in the /_N_MPF_DIR directory.
The content of the file is preserved till it is deleted with $AC_MEAS_VALID = 0.
For runtime reasons, the trace should be activated only if a problem is detected.
Extended Functions
M5: Measurement
7.5.3 Types of workpiece measurement
7.5.3.1 Measurement of an edge (measurement type 1, 2, 3)
Measurement of an x edge ($AC_MEAS_TYPE = 1)

The edge of a clamped workpiece is measured by approaching this edge with a known tool.
\ \
[ [
[ [ [ [
Figure 7-1 x edge
The values of the following variables are evaluated for measurement type 1:
Input variable Meaning

$AC_MEAS_VALID Validity bits for input variables
$AA_MEAS_POINT1[axis] Measuring point 1 for all channel axes
$AA_MEAS_SETPOINT[axis] Setpoint position of x edge *
$AC_MEAS_DIR_APPROACH 0: +x, 1: -x
$AC_MEAS_ACT_PLANE Without specification, calculation is undertaken with the
active plane,
the radius of the tool is used only in G17 and G18 *
$AC_MEAS_FINE_TRANS 0: Coarse offset, 1: Fine offset
$AC_MEAS_FRAME_SELECT Calculated as additive frame unless otherwise specified *
$AC_MEAS_T_NUMBER Calculated as active T unless otherwise specified (T0) *
$AC_MEAS_D_NUMBER Calculated as active D unless otherwise specified (D0) *
$AC_MEAS_TYPE 1
* optional
The following output variables are written for measurement type 1:
Output variable Meaning

$AC_MEAS_FRAME Result frame with translation
$AC_MEAS_RESULTS[0] Position of the measured edge
Extended Functions
M5: Measurement
Example
x edge measurement

DEF INT RETVAL
DEF FRAME TMP
$TC_DP1[1,1]=120 ; Type
$TC_DP2[1,1]=20 ; 0
$TC_DP3[1,1]=10 ; (z) length compensation vector
$TC_DP4[1,1]= 0 ; (y)
$TC_DP5[1,1]=0 ; (x)
$TC_DP6[1,1]=2 ; Radius
T1 D1
g0 x0 y0 z0 f10000
G54
; Measure x edge
$AC_MEAS_VALID = 0 ; Set all input values to invalid
g1 x-1 y-3 ; 1. Approach measuring point
$AA_MEAS_POINT1[x] = $AA_IW[x]
$AA_MEAS_POINT1[y] = $AA_IW[y]
$AA_MEAS_POINT1[z] = $AA_IW[z]
$AC_MEAS_DIR_APPROACH = 0 ; Set approach direction +x
$AA_MEAS_SETPOINT[x] = 0 ; Set setpoint position of the edge

$AA_MEAS_SETPOINT[y] = 0
$AA_MEAS_SETPOINT[z] = 0
$AC_MEAS_ACT_PLANE = 0 ; Measuring plane is G17
$AC_MEAS_FRAME_SELECT = 101 ; Select frame - IFRAME
$AC_MEAS_T_NUMBER = 1 ; Select tool

$AC_MEAS_D_NUMBER = 1
$AC_MEAS_TYPE = 1 ; Set measurement type for x edge
RETVAL = MEASURE() ; Start measuring process
Extended Functions
M5: Measurement

if RETVAL <> 0
setal(61000 + RETVAL)
endif
$P_IFRAME = $AC_MEAS_FRAME
$P_UIFR[1] = $P_IFRAME ; Describe system frame in data management
g1 x0 y0 ; Approach the edge
m30
Measurement of a y edge ($AC_MEAS_TYPE = 2)
\
\ \
\
\
[ [
\
Figure 7-2 y edge

$AA_MEAS_SETPOINT[axis] Setpoint position of y edge *
$AC_MEAS_DIR_APPROACH 2: +y, 3: -y
active plane,
$AC_MEAS_FINE_TRANS 0: Coarse offset, 1: Fine offset *
$AC_MEAS_TYPE 2
* optional
Extended Functions
M5: Measurement

Measurement of a z edge ($AC_MEAS_TYPE = 3)
]
]
Figure 7-3 z edge

$AA_MEAS_SETPOINT[axis] Setpoint position of z edge *
$AC_MEAS_DIR_APPROACH 4: +z, 5: -z
active plane,
$AC_MEAS_TYPE 3
* optional

Extended Functions
M5: Measurement
7.5.3.2 Measurement of an angle (measurement type 4, 5, 6, 7)
Measurement of a corner C1 - C4 ($AC_MEAS_TYPE = 4, 5, 6, 7)

A corner is uniquely defined by approaching four measuring points P1 to P4. Three
measuring points suffice for a known angle of intersection .
If the angle of intersection and the workpiece position angle are known, two
measurement points P1 and P3 suffice.
3
\ \
3
&
3 3 3
3 3 3
&
[ [
Figure 7-4 Corner C1, corner C2
C3 P2
y P2 P3 y
P1
P1 P4
C4
P3
P4
x x
Figure 7-5 Corner C3, corner C4
The values of the following variables are evaluated for measurement types 4 to 7:

$AA_MEAS_POINT1[axis] Measuring point 1
$AA_MEAS_POINT2[axis] Measuring point 2 irrelevant for
$AC_MEAS_WP_SETANGLE
Extended Functions
M5: Measurement

$AA_MEAS_POINT4[axis] Measuring point 4 irrelevant for
$AC_MEAS_CORNER_SETANGLE
$AA_MEAS_WP_SETANGLE Setpoint workpiece position angle *
$AA_MEAS_CORNER_SETANGLE Setpoint angle of intersection *
$AA_MEAS_SETPOINT[axis] Setpoint position of corner *
$AC_MEAS_ACT_PLANE Calculated as active plane unless otherwise specified
*
$AC_MEAS_FRAME_SELECT Calculated as additive frame unless otherwise
specified *
$AC_MEAS_T_NUMBER Calculated as active T unless otherwise specified (T0)
*
$AC_MEAS_D_NUMBER Calculated as active D unless otherwise specified
(D0) *
$AC_MEAS_INPUT[0] Without specification of outer corner *
=0: Measurement for outer corner
=1: Measurement for inner corner
$AC_MEAS_TYPE 4, 5, 6, 7
* optional
The following variables are written for measurement types 4 to 7:

$AC_MEAS_FRAME Result frame with translation and rotation
$AC_MEAS_WP_ANGLE Calculated workpiece position angle
$AC_MEAS_CORNER_ANGLE Calculated angle of intersection
$AC_MEAS_RESULTS[0] Abscissa of calculated vertex
$AC_MEAS_RESULTS[1] Ordinate of calculated vertex
$AC_MEAS_RESULTS[2] Applicate of calculated vertex
Example
Corner measurement C1: Corner with three measuring points (P1, P3 and P4) and known
angle of intersection (90) and unknown workpiece position angle .

DEF INT RETVAL
DEF FRAME TMP
$TC_DP1[1,1]=120 ; Type
$TC_DP2[1,1]=20 ; 0
$TC_DP4[1,1]=0 ; (y)
Extended Functions
M5: Measurement

$TC_DP5[1,1]=0 ; (x)
T1 D1
g0 x0 y0 z0 f10000
G54
$P_CHBFRAME[0] = crot(z,45)
$P_IFRAME[x,tr] = -sin(45)
$P_IFRAME[y,tr] = -sin(45)
$P_PFRAME[z,tr] = -45
; Measure corner with 3 measuring points

g1 x-1 y-3 ; 1. Approach measuring point

$AC_MEAS_LATCH[0] = 1 ; Pick up measuring point P1
g1 x-4 y4 ; 3. Approach measuring point


$AA_MEAS_SETPOINT[x] = 0 ; Set position setpoint of the corner to

(0, 0, 0)
$AC_MEAS_CORNER_SETANGLE = 90 ; Define setpoint angle of intersection

$AC_MEAS_FRAME_SELECT = 0 ; Select frame - SETFRAME

$AC_MEAS_TYPE = 4 ; Set measuring type on corner 1
if RETVAL <> 0
endif
Extended Functions
M5: Measurement

if $AC_MEAS_CORNER_ANGLE <> 90 ; Query known setpoint angle of
intersection
setal(61000 + $AC_MEAS_CORNER_ANGLE)
endif
$P_SETFRAME = $AC_MEAS_FRAME
$P_SETFR = $P_SETFRAME ; Describe system frame in data management
g1 x0 y0 ; Approach the corner
g1 x10 ; Approach the rectangle

y10
x0
y0
m30
7.5.3.3 Measurement of a hole (measurement type 8)
Measuring points for determining a hole ($AC_MEAS_TYPE = 8)

Three measuring points are needed to determine the center point and diameter. The three
points must all be different. When four points are specified, the circle is adjusted in
accordance with the least square method. The circle is determined so that the sum of the
distance squares of the points to the circle is minimal. The quality of the adjustment can be
read.
\ * [ * ] *

' ' '

[ ] \
Figure 7-6 Hole
Extended Functions
M5: Measurement

$AA_MEAS_POINT4[axis] When specified, the center is determined from four
points *
$AA_MEAS_SETPOINT[axis] Setpoint position of hole center *
$AC_MEAS_ACT_PLANE Calculated as active plane unless otherwise specified *
$AC_MEAS_FRAME_SELECT Calculated as additive frame unless otherwise
specified *
$AC_MEAS_T_NUMBER Calculated as active T unless otherwise specified (T0)
*
$AC_MEAS_D_NUMBER Calculated as active D unless otherwise specified (D0)
*
$AC_MEAS_TYPE 8
* optional

$AC_MEAS_DIAMETER Diameter of hole
$AC_MEAS_RESULTS[0] Abscissa of the calculated center point
$AC_MEAS_RESULTS[1] Ordinate of the calculated center point
$AC_MEAS_RESULTS[2] Applicate of the calculated center point
$AC_MEAS_RESULTS[3] Quality of the circle adjustment: Sum of the distance
squares
Example
Measuring a hole

DEF INT RETVAL
DEF FRAME TMP
$TC_DP1[1,1]=120 ; Type
$TC_DP2[1,1]=20 ; 0
$TC_DP4[1,1]=0 ; (y)
$TC_DP5[1,1]=0 ; (x)
Extended Functions
M5: Measurement
T1 D1
g0 x0 y0 z0 f10000
G54
: Measure hole

g1 x0 y3 ; 2. Approach measuring point

g1 x3 y0 ; 3. Approach measuring point

$AA_MEAS_SETPOINT[x] = 0 ; Set setpoint position of the center



$AC_MEAS_TYPE = 8 ; Set measuring type on hole

if RETVAL <> 0
endif
if $AC_MEAS_DIAMETER <> 10 ; Query known diameter

setal(61000 + $AC_MEAS_WP_ANGLE)
endif
Extended Functions
M5: Measurement

g1 x-3 y0 ; Approach P1
g2 I = $AC_MEAS_DIAMETER / 2 ; Approach hole in reference to the center of

the circle
m30
7.5.3.4 Measurement of a shaft (measurement type 9)
Measuring points for determining a shaft ($AC_MEAS_TYPE = 9)

Three measuring points are needed to determine the center point and diameter. The three
points must all be different. When four points are specified, the circle is adjusted in
accordance with the least square method. The circle is determined so that the sum of the
distance squares of the points to the circle is minimal. The quality of the adjustment can be
read.
\ * [ * ] *

'
' '

[ ] \
Figure 7-7 Shaft

Extended Functions
M5: Measurement

$AA_MEAS_POINT4[axis] When specified, the center is determined from four points
*
$AA_MEAS_SETPOINT[axis] Setpoint position of shaft center point *
$AC_MEAS_TYPE 9
* optional

$AC_MEAS_DIAMETER Diameter of hole
$AC_MEAS_RESULTS[3] Quality of the circle adjustment: Sum of the distance
squares
7.5.3.5 Measurement of a groove (measurement type 12)
Measuring points for determining the position of a groove ($AC_MEAS_TYPE = 12)

A groove is measured by approaching the two outside corners or inner edges. The groove
center can be set to a setpoint position. The component of the approach direction
determines the groove position.
\ \
\
[ [ \
\
[ [ [
Figure 7-8 Groove
Extended Functions
M5: Measurement

$AA_MEAS_SETPOINT[axis] Setpoint position of groove center *
$AC_MEAS_DIR_APPROACH 0: +x, 1: -x, 2: +y, 3: -y, 4: +z, 5: -z
$AC_MEAS_INPUT[0] Approach direction for 2nd measuring point for a recess
measurement. Must have the same coordinate as the
approach direction of the 1st point. *
0: +x, 1: -x, 2: +y, 3: -y, 4: +z, 5: -z
$AC_MEAS_TYPE 12
* optional

$AC_MEAS_RESULTS[0] Position of calculated groove center (x0, y0 or z0)
$AC_MEAS_RESULTS[1] Groove width in approach direction
Example
Groove measurement with approach direction in x

DEF INT RETVAL
DEF FRAME TMP
$TC_DP1[1,1]=120 ; Type
$TC_DP2[1,1]=20 ; 0
$TC_DP4[1,1]=0 ; (y)
$TC_DP5[1,1]=0 ; (x)
T1 D1
g0 x0 y0 z0 f10000
G54
Extended Functions
M5: Measurement

$P_CHBFRAME[0] = crot(z,45)
$P_IFRAME[x,tr] = -sin(45)
$P_IFRAME[y,tr] = -sin(45)
$P_PFRAME[z,rt] = -45
; Measure groove
g1 x-2 ; 1. Approach measuring point

g1 x4 ; 2. Approach measuring point

$AA_MEAS_SETPOINT[x] = 0 ; Set setpoint position of the groove center

$AC_MEAS_DIR_APPROACH = 0 ; Set approach direction +x


$AC_MEAS_TYPE = 12 ; Set measuring type on groove
if RETVAL <> 0 setal(61000 + RETVAL)

endif
g1 x0 y0 ; Approach the groove center
m30
Extended Functions
M5: Measurement
7.5.3.6 Measurement of a web (measurement type 13)
Measuring points for determining the position of a web ($AC_MEAS_TYPE = 13)

A web is measured by approaching the two outside corners or inner edges. The web center
can be set to a setpoint position. The component of the approach direction determines the
web position.
\
\ \
[ [ \
[ [ \ [
Figure 7-9 Web

$AA_MEAS_SETPOINT[axis] Setpoint position of web center *
$AC_MEAS_INPUT[0] Approach direction for 2nd measuring point for a recess
measurement. Must have the same coordinate as the
approach direction of the 1st point. *
0: +x, 1: -x, 2: +y, 3: -y, 4: +z, 5: -z
$AC_MEAS_TYPE 13
* optional
Extended Functions
M5: Measurement

$AC_MEAS_RESULTS[0] Position of calculated web center (x0, y0 or z0)
$AC_MEAS_RESULTS[1] Web width in approach direction
7.5.3.7 Measurement of geo axes and special axes (measurement type 14, 15)
Preset actual value memory for geo axes and special axes ($AC MEAS TYPE = 14)
This measurement type is used on the HMI operator interface.
6SHFLDOD[HV
]
$6HW $6HW $6HW
< 3$FW $
]L $FW
$$FW
\L
$$FW
36HW
[V\V]V [L [
Figure 7-10 Preset actual value memory

$AA_MEAS_POINT1[axis] Actual values of the axes
$AA_MEAS_SETPOINT[axis] Setpoint position of the individual axes *
$AC_MEAS_TYPE 14
* optional

$AC_MEAS_FRAME Result frame with translations
Extended Functions
M5: Measurement
Example
Reference point setting in relative coordinate systems.

DEF INT RETVAL
T1 D1 ; Activate probe
G54 ; Activate all frames and G54
TRANS x=10 ; Offset between WCS and ENS

G0 x0 f10000 ; WCS(x) = 0; ENS(x) = 10
$AC_MEAS_VALID = 0 ; Set all input variables to invalid

$AC_MEAS_TYPE = 14 ; Measuring type for preset actual value
memory
$AC_MEAS_P1_COORD = 5 ; ENS_REL for 1st measuring point

$AC_MEAS_LATCH[0] = 1 ; Pick up all axis positions
$AC_MEAS_SET_COORD = 5 ; Setpoint position is relative to ENS

$AA_MEAS_SETPOINT[x] = 0 ; Setpoint position in the relative ENS
coordinate system
$AC_MEAS_FRAME_SELECT = 2505 ; $P_RELFR
RETVAL = MEASURE() ; Calculation of $P_RELFR; PI SETUDT(6)

IF RETVAL <> 0 GOTOF ERROR
ENDIF $ P_RELFR = $AC_MEAS_FRAME ; Activation; PI SETUDT(7)
Preset actual value memory for special axes only ($AC MEAS TYPE = 15)
This measurement type is used on the HMI operator interface.
6SHFLDOD[HV
$6HW $6HW $6HW
$$FW
$$FW
$$FW
Figure 7-11 Preset actual value memory for special axes only
Extended Functions
M5: Measurement

$AA_MEAS_POINT1[axis] Actual values of the axes
$AA_MEAS_SETPOINT[axis] Setpoint position of the individual axes *
$AC_MEAS_TYPE 15
* optional

$AC_MEAS_FRAME Result frame with translations
7.5.3.8 Measurement of an oblique edge (measurement type 16)
Measurement of an oblique edge ($AC_MEAS_TYPE = 16)

This measurement determines the position angle of the workpiece and enters it in the frame.
A setpoint angle in the +/- 90 degrees range can be input. This can be interpreted as the
resultant rotation of the workpiece after the result frame for the active WCS has been
activated.
* * *

< [ 5HIHUHQFHD[LV ]
3
3 3 3
3 3
[ ] <
Figure 7-12 Oblique edge in planes G17, G18 and G19
Extended Functions
M5: Measurement

$AA_MEAS_SETANGLE Setpoint angle *
$AC_MEAS_INPUT[0] Unless otherwise specified, the reference coordinate for the
alignment of the workpiece is always the abscissa of the
selected plane. *
=0: Reference coordinate is the abscissa
=1: Reference coordinate is the ordinate
$AC_MEAS_INPUT[1] Unless otherwise specified, the workpiece position angle is
entered in the frame as a rotation. Otherwise, a channel axis
index can be specified for a rotary axis whose translation is set
to the current rotary axis position plus the calculated rotation.
The workpiece is then aligned at rotary axis position = 0. The
current rotary axis value must be set in
$AA_MEAS_POINT[axis]. *
$AC_MEAS_TYPE 16
* optional

$AC_MEAS_FRAME Result frame with rotation
Extended Functions
M5: Measurement
7.5.3.9 Measurement of an oblique angle in a plane (measurement type 17)
Measurement of an angle in an inclined plane ($AC_MEAS_TYPE = 17)

The oblique plane is determined using three measuring points P1, P2 and P3.
$&B0($6B5(68/76>@
3
3
\ 3
] \

$&B0($6B5(68/76>@
Figure 7-13 Oblique plane in G17
$AC_MEAS_TYPE = 17 defines two resulting angles 0 and 1 for the skew of the plane;
these are entered in $AC_MEAS_RESULTS[0..1]:
$AC_MEAS_RESULTS[0] Rotation at the abscissa
$AC_MEAS_RESULTS[1] Rotation at the ordinate
These angles are calculated by means of the three measuring points P1, P2 and P3. In this
type of measurement the angle for the applicate ($AC_MEAS_RESULTS[2]) is always pre-
filled with 0.
A setpoint rotation that is entered in the result frame can be input for the abscissa and/or the
ordinate. If only one angle is specified with a setpoint, the second angle is calculated such
that the three measuring points are on an oblique plane with the setpoint angle. Only
rotations are entered in the result frame, the WCS reference point is retained. The WCS is
rotated such that z' is perpendicular to the oblique plane.
The following plane settings are defined for measurement type 17:
Axis identifier G17 G18 G19

Abscissa x axis z axis y axis
Ordinate y axis x axis z axis
Applicate (infeed axis) z axis y axis x axis
Extended Functions
M5: Measurement

$AA_MEAS_SETANGLE[axis] Setpoint rotations around abscissa and ordinate *
$AC_MEAS_INPUT[0] Unless otherwise specified,
the points are not projected in a plane *
0: Points are not projected on a plane
1: Points are projected in the active plane or in the selected
plane
$AC_MEAS_TYPE 17
* optional

$AC_MEAS_FRAME Result frame
$AC_MEAS_RESULTS[0] Angles around abscissa from which three measuring points are
calculated
$AC_MEAS_RESULTS[1] Angles around ordinate from which three measuring points are
calculated
$AC_MEAS_RESULTS[2] Angles around applicate from which three measuring points are
calculated
$AC_MEAS_RESULTS[3] Angle around abscissa which is entered in the result frame
$AC_MEAS_RESULTS[4] Angle around ordinate which is entered in the result frame
$AC_MEAS_RESULTS[5] Angle around applicate which is entered in the result frame
Example
Measure angle of a plane.

DEF INT RETVAL
DEF AXIS _XX, _YY, _ZZ
Extended Functions
M5: Measurement

$AC_MEAS_TYPE = 17 ; Set measurement type for oblique plane
_XX=$P_AXN1 ; Define axes according to the plane

_YY=$P_AXN2
_ZZ=$P_AXN3
G17 G1 _XX=10 _YY=10 F1000 ; 1. Approach measuring point

MEAS = 1 _ZZ=...
$AA_MEAS_POINT1[_xx] = $AA_MW[_xx] ; Assign measurement value to abscissa
$AA_MEAS_POINT1[_yy] = $AA_MW[_yy] ; Assign measurement value to ordinate
$AA_MEAS_POINT1[_zz] = $AA_MW[_zz] ; Assign measurement value to applicate
G1 _XX=20 _YY=10 F1000 ; 2. Approach measuring point

MEAS = 1 _ZZ=...

MEAS = 1 _ZZ=...
; Define setpoints for angle

$AA_MEAS_SETANGLE[_xx] = 12 ; Rotation around the abscissa
$AA_MEAS_SETANGLE[_yy] = 4 ; Rotation around the ordinate
$AC_MEAS_FRAME_SELECT = 102 ; Select target frame - G55

RETVAL = MEASURE() ; Start measurement calculation
if RETVAL <> 0
endif
if $AC_MEAS_RESULTS[0] <> 12
setal(61000 + $AC_MEAS_RESULTS[0])
endif
Extended Functions
M5: Measurement

if $AC_MEAS_RESULTS[1] <> 4
setal(61000 + $AC_MEAS_RESULTS[1])
endif
$P_UIFR[2] = $AC_MEAS_FRAME ; Write measurement frame in data management

(G55)
G55 G0 AX[_xx]=10 AX[_yy]=10 ; Activate frame and traverse

m30
7.5.3.10 Redefine measurement around a WCS reference frame (measurement type 18)
Redefine WCS coordinate system ($AC_MEAS_TYPE = 18)

The zero point of the new WCS is determined by measuring point P1 at surface normal on
the oblique plane.
$&B0($6B5(68/76>@
] ]
$&B0($6B5(68/76>@

3
[
3
<
:&6
3

$&B0($6B5(68/76>@
:&6 [
Figure 7-14 Oblique plane in G17
Extended Functions
M5: Measurement
Measurement of plane
The plane is measured in one measuring cycle. The cycle records the three measuring
points and passes the necessary values to the variable interface.
The MEASURE() function calculates the solid angles and translational offset of the new
WCS' on the basis of the input values.
Transformation of measuring frame

The results of the calculation, i.e. the solid angles and translation, are entered in measuring
frame $AC_MEAS_FRAME. The measuring frame is transformed according to the selected
frame in the frame chain. The solid angles are also stored in the output values
$AC_MEAS_RESULTS[0..2]. In
The angle around the abscissa of the old WCS is stored in $AC_MEAS_RESULTS[0],
The angle around the ordinate is stored in $AC_MEAS_RESULTS[1] and
The angle around the applicate is stored in $AC_MEAS_RESULTS[2].
Define the new WCS' zero

After performing the calculation, the measuring cycle can write and activate the selected
frame in the frame chain with the measuring frame. After activation, the new WCS is
positioned at surface normal on the inclined plane, with measuring point P1 as the zero point
of the new WCS.
The programmed positions then refer to the inclined plane.
Application
CAD systems often define inclined planes by specifying three points P1, P2 and P3 on this
plane. In this case,
1. measuring point P1 is applied as the new WCS' reference point,
2. Measuring point P2 defines the direction of the abscissa x' of the newly rotated WCS'
coordinate system and the
3. measuring point P3 is used to determine the solid angles.

$AA_MEAS_SETPOINT[axis] Setpoint position of P1 *
Extended Functions
M5: Measurement

$AC_MEAS_INPUT[0] Unless otherwise specified,
the points are not projected in a plane *
0: Points are not projected on a plane
1: Points are projected in the active plane or in the selected
plane
$AC_MEAS_TYPE 18
* optional

$AC_MEAS_FRAME Result frame with rotations and transformation
$AC_MEAS_RESULTS[0] Calculated angle around the abscissa
$AC_MEAS_RESULTS[1] Calculated angle around the ordinate
$AC_MEAS_RESULTS[2] Calculated angle around the applicate
Example
Workpiece coordinate system on the inclined plane

DEF INT RETVAL

$AC_MEAS_TYPE = 18 ; Set measurement type for oblique plane

_YY=$P_AXN2
_ZZ=$P_AXN3
G17 G1 _XX=10 _YY=10 F1000 ; 1. Approach measuring point

MEAS = 1 _ZZ=...

Extended Functions
M5: Measurement

MEAS = 1 _ZZ=...


MEAS = 1 _ZZ=...

$AA_MEAS_SETPOINT[_xx] = 10 ; Define setpoints for P1

$AA_MEAS_SETPOINT[_yy] = 10
$AA_MEAS_SETPOINT[_zz] = 10


if RETVAL <> 0
endif
; Calculation results for the solid angles

; Angle around the
R0 = $AC_MEAS_RESULTS[0] ; Abscissa for the old WCS
R1 = $AC_MEAS_RESULTS[1] ; Ordinate
R2 = $AC_MEAS_RESULTS[2] ; Applicate

(G55)

m30
Extended Functions
M5: Measurement
7.5.3.11 Measurement of a 1-, 2- and 3-dimensional setpoint selection (measurement type 19,
20, 21)
1-dimensional setpoint value ($AC_MEAS_TYPE = 19)

With this measurement method, it is possible to define exactly one setpoint for the abscissa,
the ordinate and the applicate. If two or three setpoints are defined, only the first is accepted
in the sequence abscissa, ordinate and applicate. The tool is not taken into account.
It is purely an actual value memory preset for the abscissa, the ordinate or the applicate.

$AA_MEAS_POINT1[axis] Measuring point 1 for the abscissa
$AA_MEAS_POINT1[axis] Measuring point 1 for the ordinate
$AA_MEAS_POINT1[axis] Measuring point 1 for the applicate
$AA_MEAS_SETPOINT[axis] Setpoint position of abscissa or ordinate or applicate
$AC_MEAS_FINE_TRANS Unless otherwise specified, frame is written to coarse translation
*
$AC_MEAS_TYPE 19
* optional

$AC_MEAS_FRAME Result frame with rotations and translation
Example
1-dimensional setpoint selection

DEF INT RETVAL
DEF REAL _CORMW_XX,
_CORMW_YY,
_CORMW_ZZ
$AC_MEAS_TYPE = 19 ; Set measurement type for 1-dimensional
setpoint selection
Extended Functions
M5: Measurement

_YY=$P_AXN2
_ZZ=$P_AXN3
; Assign measured values
$AA_MEAS_SETPOINT[_xx] = 10 ; Define setpoint for abscissa
if RETVAL <> 0
endif
(G55)
m30

Setpoints for two dimensions can be defined using this measuring method. Any combination
of 2 out of 3 axes is permissible. If three setpoints are specified, only the values for the
abscissa and the ordinate are accepted. The tool is not taken into account.
This is a purely actual value memory preset.

$AA_MEAS_SETPOINT[axis] Setpoint position for the 1st dimension
$AA_MEAS_SETPOINT[axis] Setpoint position for the 2nd dimension
*
$AC_MEAS_TYPE 20
* optional
Extended Functions
M5: Measurement

Example

DEF INT RETVAL
DEF REAL _CORMW_XX,
_CORMW_YY,
_CORMW_ZZ
setpoint selection
_YY=$P_AXN2
_ZZ=$P_AXN3
$AA_MEAS_SETPOINT[_xx] = 10 ; Define setpoint for abscissa and ordinate
if RETVAL <> 0
endif
(G55)
m30
Extended Functions
M5: Measurement

Using this measurement method, it is possible to define a setpoint for the abscissa, the
ordinate and the applicate. The tool is not taken into account.
It is purely an actual value memory preset for the abscissa, ordinate and applicate.

$AA_MEAS_SETPOINT[axis] Setpoint position for the abscissa
$AA_MEAS_SETPOINT[axis] Setpoint position for the ordinate
$AA_MEAS_SETPOINT[axis] Setpoint position for the applicate
*
$AC_MEAS_TYPE 21
* optional

Example

DEF INT RETVAL
DEF REAL _CORMW_XX,
_CORMW_YY,
_CORMW_ZZ
setpoint selection
Extended Functions
M5: Measurement

_YY=$P_AXN2
_ZZ=$P_AXN3
$AA_MEAS_SETPOINT[_xx] = 10 ; Define setpoint for abscissa, ordinate and
applicate
$AA_MEAS_SETPOINT[_yy] = 10 ; Define
$AA_MEAS_SETPOINT[_zz] = 10
if RETVAL <> 0
endif
(G55)
m30
7.5.3.12 Measuring a measuring point in any coordinate system (measurement type 24)
Measurement method for converting a measuring point in any coordinate system ($AC_MEAS_TYPE
= 24)
With this method of measurement, a measuring point in any coordinate system (WCS, BCS,
MCS) can be converted with reference to a new coordinate system by coordinate
transformation.
The new coordinate system is generated by specifying a desired frame chain.
Extended Functions
M5: Measurement
30&6 3
0&6
<
:&6
6SHFLILHGIUDPH
%&6 [
Figure 7-15 Coordinate transformation of a position

$AA_MEAS_POINT1[axis] Position to be transformed
$AC_MEAS_P1:COORD Default is 0: WCS, 1: BCS, 2: MCS *
$AC_MEAS_P2_COORD Target coordinate system *
$AC_MEAS_TOOL_MASK 0x20; Length of the active tool is included in the coordinate
transformation of a position *
$AC_MEAS_CHSFR System frames from data management *
$AC_MEAS_NCBFR Global basic frames from the data management *
$AC_MEAS_CHBFR Channel basic frames from the data management *
$AC_MEAS_UIFR Settable frame from data management *
$AC_MEAS_PFRAME 1: Programmable frame is not included in calculation *
$AC_MEAS_TYPE 24
* optional

$AC_MEAS_POINT2[axis] Converted axis positions
Extended Functions
M5: Measurement
Example
WCS coordinate transformation of a measured position

DEF INT RETVAL
DEF INT LAUF
DEF REAL_CORMW_xx, _CORMW_yy, _CORMW_zz
$TC_DP1[1,1]=120 ; Tool type end mill

$TC_DP2[1,1]=20
$TC_DP4[1,1]=0 ; (y) length compensation vector
$TC_DP5[1,1]=0 ; (x) length compensation vector
G17 ; Oblique plane G17
_xx=$P_AXN1 _yy=$P_AXN2 _zz=$P_AXN3 ; Define axes according to the plane
; Entire frame results in

CTRANS(_xx,10,_yy,-1,_zz,5,A,6,B,7)
$P_CHBFR[0]=CTRANS(_zz,5,A,6) : CROT(_zz,45)
$P_UIFR[1]=CTRANS( )
$P_UIFR[1,_xx,TR]=-SIN(45)
$P_UIFR[1,_yy,TR]=-SIN(45)
$P_UIFR[2]=CTRANS( )
$P_PFRAME=CROT(_zz,-45)
$P_CYCFR=CTRANS(_xx,10,B,7)

G0 X0 Y0 Z0 A0 B0 F1000

$AC_MEAS_TYPE = 24 ; Set measurement type for coordinate
transformation

$AA_MEAS_POINT1[_xx] = $AA_IW[_xx] ; Assign measurement value to abscissa
$AA_MEAS_POINT1[_yy] = $AA_IW[_yy] ; Assign measurement value to ordinate
$AA_MEAS_POINT1[_zz] = $AA_IW[_zz] ; Assign measurement value to applicate
$AA_MEAS_POINT1[A] = $AA_IW[A]
$AA_MEAS_POINT1[B] = $AA_IW[B]
Extended Functions
M5: Measurement

$AC_MEAS_P1_COORD=0 ; Converting a position from WCS into WCS'
$AC_MEAS_P2_COORD=0
; Set WCS
; Entire frame results in
CTRANS(_xx,0,_yy,0,_zz,5,A,6,B,0)
; Stop cycle frame
$AC_MEAS_CHSER=$MC_MM_SYSTEM_FRAME_MASK B_AND 'B1011111'
$AC_MEAS__NCBFR='B0' ; Stop global basic frame
$AC_MEAS__CHBFR='B1' ; Channel basic frame 1 from data management
$AC_MEAS__UIFR=2 ; Settable frame G55 from data management
$AA_MEAS_PFRAME=1 ; Do not include programmable frame in
calculation

if RETVAL <> 0
endif
if $AA_MEAS_PIONT2[_xx] <> 10
setal(61000)
M0
stopre
endif
if $AA_MEAS_PIONT2[_yy] <> -1
setal(61000)
M0
stopre
if $AA_MEAS_PIONT2[_zz] <> 0
setal(61000)
M0
stopre
if $AA_MEAS_PIONT2[A] <> 0
setal(61000)
M0
stopre
if $AA_MEAS_PIONT2[B] <> 7
setal(61000)
M0
stopre
m30
Extended Functions
M5: Measurement
7.5.3.13 Measurement of a rectangle (measurement type 25)
Measuring points for determining a rectangle ($AC_MEAS_TYPE = 25)

To determine a rectangle, tool dimensions are required in the following working planes.
G17 working plane x/y infeed direction z
G18 working plane z/x infeed direction y
G19 working plane y/z infeed direction x
Four measuring points are required per rectangle.
Measuring points can be specified in any desired order. The measuring points with the
largest ordinate distance correspond to points P3 and P4.
* * *
\ [ ]
3 3 3
3 3 3
3 3 3
3 [ 3 ] 3 \
Figure 7-16 Determining a rectangle with infeed into the working plane G17, G18 and G19

$AA_MEAS_SETPOINT[axis] Setpoint position of web center *
Extended Functions
M5: Measurement

$AC_MEAS_INPUT[0] Without specification of outer corner *
=0: Measurement for outer corner
=1: Measurement for inner corner
$AC_MEAS_TYPE 25
* optional

$AC_MEAS_RESULTS[3] Width of rectangle P1/P2
$AC_MEAS_RESULTS[4] Length of rectangle P3/P4
7.5.3.14 Measurement for saving data management frames (measurement type 26)
Saving data management frames ($AC_MEAS_TYPE = 26)

This measurement type offers the option of saving some or all data management frames with
their current value assignments to a file. The measurement can be initiated by executing a
command or via the part program. The function can also be activated from different
channels. The files are set up in directory _N_SYF_DIR.
A Restore operation deletes the backed-up data and a new Save operation overwrites the
existing back-up. The data last saved can then be deleted with
$AC_MEAS_CHSFR = 0 system frames;
$AC_MEAS_NCBFR = 0 global basic frames;
$AC_MEAS_CHBFR = 0 channel basic frames;
$AC_MEAS_UIFR = 0 number of settable frames
from the data management system using a second Save operation.
Note
If you decide to create a backup of all data management frames, remember that 1 KB of
memory is needed to save each frame. If insufficient memory is available, the process is
aborted with error message MEAS_NO_MEMORY. The following machine data item can be
used to change the size of the static memory:
MD18351 $MM_DRAM_FILE_MEM_SIZE
Extended Functions
M5: Measurement

$AC_MEAS_CHSFR Bit mask system frames from data management. *
If this variable is not written, all system frames are backed up.
$AC_MEAS_NCBFR Bit mask of global basic frames from the data management. *
If this variable is not written, all global basic frames are backed
up.
$AC_MEAS_CHBFR Bit mask of channel basic frames from the data management. *
If this variable is not written, all channel basic frames are
backed up.
$AC_MEAS_UIFR Number of settable frames from data management. *
0..100: 1: G500 2: G500, G54.
If this variable is not written, all settable frames are backed up.
$AC_MEAS_TYPE 26
* optional
7.5.3.15 Measurement for restoring backed-up data management frames (measurement type
27)
Restoring data management frames last backed up ($AC_MEAS_TYPE = 27)

This measurement type allows data management frames backed up by measurement type
26 to be restored to the SRAM.
It is possible to restore either some or all of the frames last backed up. If a frame that has not
been backed up is selected, the selection is ignored. The process is not aborted.

$AC_MEAS_CHSFR Bit mask system frames from data management. *
If this variable is not written, all system frames are restored.
$AC_MEAS_NCBFR Bit mask of global basic frames from the data management. *
If this variable is not written, all global basic frames are
restored.
$AC_MEAS_CHBFR Bit mask of channel basic frames from the data management. *
If this variable is not written, all channel basic frames are
restored.
Extended Functions
M5: Measurement

$AC_MEAS_UIFR Number of settable frames from data management. *
Range of 1: G54 to G99: G599.
If this variable is not written, all settable frames are restored.
$AC_MEAS_TYPE 27
* optional
7.5.3.16 Measurement for defining an additive rotation for taper turning (measurement type 28)
Additive rotation of the plane for taper turning ($AC_MEAS_TYPE = 28)

Measuring type 28 can be used to specify an additive rotation through an angle in the range
of = +/- 90 of the active or a certain plane. The rotation takes place on the coordinate axis
at right angles to the plane.
\ [ ]
\
[
]
* * *
[
]
\
[ ] \
Figure 7-17 Rotation of the planes G17, G18 and G19 by angle = +30
Application
With taper turning, the active plane is rotated by the taper angle, whereby the rotation is
written in the active cycle frame. With RESET, the cycle frame is deleted. Re-activation may
be necessary. The selection of the cycle frame is made depending on the SZS position
display. If after activation of the rotation, e.g. with active plane G18, traversing is performed
in the direction of z', the actual positions of the corresponding axes change simultaneously
for x and z
Rotations with active planes G17 and G19 behave similarly and are displayed in the above
figure. The values of the following variables are evaluated for measurement type 28:

$AC_MEAS_WP_SETANGLE Setpoint angle
$AC_MEAS_ACT_PLANE Rotation is through the active plane unless otherwise specified *
$AC_MEAS_INPUT[0] 1: Taper turning is active. *
$AC_MEAS_TYPE 28
* optional
Extended Functions
M5: Measurement

$AC_MEAS_FRAME Result with rotation
7.5.4 Tool measuring

The control calculates the distance between the tool tip and the tool carrier reference point T
from the tool length specified by the user.
The following measurement types can be used to measure a tool loaded on a turning or
milling machine:
Measurement types Tool measuring

$AC_MEAS_TYPE = 10 Tool lengths on a reference part that has already been measured
$AC_MEAS_TYPE = 11 Tool diameter on a reference part that has already been measured
$AC_MEAS_TYPE = 22 Tool diameters on machines with zoom-in function (ShopTurn)
$AC_MEAS_TYPE = 23 Tool lengths with stored or current positions (ShopTurn)
Measurement of a tool length of two tools with the following orientation:
Two turning tools with:
Their own reference point each for tool orientation in the approach
direction.
One reference point for tool position that is opposite to the approach
direction and tool orientation.
Two milling tools with:
Their own reference point each for tool orientation in -y.
One reference point for tool position in -y and a tool position opposite to
the approach direction.
Two milling tools rotated 90 degrees with:
Their own reference point each for tool orientation in the approach
direction.
One reference point for a tool position that is opposite to the approach
direction and tool orientation.
Extended Functions
M5: Measurement
7.5.5 Types of workpiece measurement
7.5.5.1 Measurement of tool lengths (measurement type 10)
Tool length measurement on a reference part that has already been measured ($AC_MEAS_TYPE =
10)
The tool length can be measured on a previously measured reference part.
The plane selection depends on the position of the tool:
G17 for tool position in the z direction
G18 for tool position in the y direction
G19 for tool position in the x direction
* * *
] \ [
] \ [
] \ [
[ ] \
] \ [
Figure 7-18 Tool length measurement for the selected plane G17, G18 and G19

$AC_MEAS_P1_COORD Coordinate system of the measuring point *
$AA_MEAS_SETPOINT[axis] Set position z0
$AC_MEAS_SET_COORD Coordinate system of setpoint *
Extended Functions
M5: Measurement

$AC_MEAS_TYPE 10
* optional

$AC_MEAS_TOOL_LENGTH Tool length
$AC_MEAS_RESULTS[0] Tool length in x
$AC_MEAS_RESULTS[1] Tool length in y
$AC_MEAS_RESULTS[2] Tool length in z
$AC_MEAS_RESULTS[3] Tool length L1
Example
Measuring the tool length

DEF INT RETVAL
T0 D0
g0 x0 y0 z0 f10000
; Measure tool length
g1 z10 ; Move tool towards reference part
$AC_MEAS_LATCH[0] = 1 ; Pick up measuring point 1

$AC_MEAS_DIR_APPROACH = 5 ; Set approach direction -z
$AA_MEAS_SETPOINT[x] = 0 ; Set reference position
$AC_MEAS_T_NUMBER = 0 ; No tool has been selected
$AC_MEAS_TYPE = 10 ; Set measuring type on tool length
RETVAL = MEASURE() , Start measuring process

if RETVAL <> 0 setal(61000 + RETVAL)
endif
if $AC_MEAS_TOOL_LENGTH <> 10 ; Query known tool length
setal(61000 + $AC_MEAS_TOOL_LENGTH)
endif
m30
Extended Functions
M5: Measurement
7.5.5.2 Measurement of tool diameter (measurement type 11)
Tool diameter measurement on a reference part ($AC_MEAS_TYPE = 11)

The tool diameter can be measured on a reference part that has already been measured.
Depending on the position of the tool, it is possible to select plane G17 for tool position in the
z direction, G18 for tool position in the y direction and G19 for tool position in the x direction.
] ]
* *
[ [ \ \
[ [ \ [
\ \
* *
[ [ ] ]
[ [ ] ]
[ [
* *
\ \ ] ]
\ \ ] ]
Figure 7-19 Tool diameter for selected planes G17, G18 and G19

$AA_MEAS_SETPOINT[axis] Set position x0
$AC_MEAS_TYPE 11
* optional
Extended Functions
M5: Measurement

$AC_MEAS_TOOL_DIAMETER Tool diameter
7.5.5.3 Measurement of tool lengths with zoom-in function (measurement type 22)
Tool length with zoom-in function

Tool length measurement with zoom-in function ($AC_MEAS_TYPE = 22)
If a zoom-in function is available on the machine, it can be used to determine the tool
dimensions.
[ [
] ]
Figure 7-20 Measurement of tool lengths with zoom-in function
Input variable Description

$AA_MEAS_SETPOINT[axis] Zoom positions x and z must be specified
$AC_MEAS_TYPE 22
* optional
Extended Functions
M5: Measurement
Output variable Description

$AC_MEAS_RESULT[0] Tool length in x
$AC_MEAS_RESULT[1] Tool length in y
$AC_MEAS_RESULT[2] Tool length in z
$AC_MEAS_RESULT[3] Tool length L1
7.5.5.4 Measuring a tool length with stored or current position (measurement type 23)
Tool length with stored / current position

Tool length measurement with stored or current position ($AC_MEAS_TYPE = 23)
In the case of manual measurement, the tool dimensions can be determined in the X and Z
directions. From the known position of the
Tool carrier reference point and the
Workpiece dimensions
ShopTurn calculates the tool offset data.
[ [
[
] ]
]
Figure 7-21 Measurement of a tool length with a stored or actual position
Extended Functions
M5: Measurement
The values of the following input variables are evaluated for measurement type 23:
Input variable Description

$AA_MEAS_POINT1[axis] Current or marked position
$AA_MEAS_SETPOINT[axis] Setpoint position (minimum one geo axis must be specified)
$AC_MEAS_TOOL_MASK Tool position, radius *
$AC_MEAS_DIR_APPROACH Approach direction *
$AC_MEAS_INPUT[0] = 1 the calculated tool lengths are written to the data management *
$AC_MEAS_TYPE 23
* optional
Output variable Description

$AC_MEAS_RESULT[0] Tool length in x
$AC_MEAS_RESULT[1] Tool length in y
$AC_MEAS_RESULT[2] Tool length in z
Extended Functions
M5: Measurement
7.5.5.5 Measurement of a tool length of two tools with the following orientation:
Tool orientation
For tools whose orientation points to the toolholder shows must be set in the system
variables $AC_MEAS_TOOL_MASK, bit 9 = 1 (0x200). The calculated tool lengths are then
included negatively.
Two turning tools each with their own reference point with a tool orientation in the approach direction
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:=/ :=/
Settings in the system data:
Left-hand tool: Approach direction and tool orientation +x

$AC_MEAS_TOOL_MASK = 0x2 Tool position in x direction (G19)
$AC_MEAS_DIR_APPROACH = 0 Approach direction +x
Right-hand tool: Approach direction and tool orientation -x

$AC_MEAS_TOOL_MASK = 0x40 Tool position in the -x direction
$AC_MEAS_DIR_APPROACH = 1 Approach direction -x
For both tools

$AC_MEAS_Px_COORD = 1 Coordinate system of x-th measuring point = BCS
$AC_MEAS_SET_COORD = 1 Coordinate system of the setpoint = BCS
Extended Functions
M5: Measurement
Two turning tools each with their own reference point with a tool counter-orientation in the approach
direction
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$AC_MEAS_TOOL_MASK = 0x2 + 0x200 Tool position in x direction (G19) +
Tool length differential values are included
negatively

For both tools

Extended Functions
M5: Measurement
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$AC_MEAS_TOOL_MASK = 0x40 + 0x200 Tool position in x direction +
Tool length differential values are included
negatively
For both tools

Extended Functions
M5: Measurement
Two milling tools each with their own reference point, tool orientation perpendicular to the approach
direction
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Left-hand tool: Approach direction +x and tool orientation -y

$AC_MEAS_TOOL_MASK = 0x80 Tool position in -y direction
Right-hand tool: Approach direction -x and tool orientation -y

For both tools

Extended Functions
M5: Measurement
Two milling tools each with a reference point, tool orientation perpendicular to the approach direction
Two milling tools with one reference point with a tool orientation in -y
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In the present layout, the tool position $AC_MEAS_TOOL_MASK and approach direction to
the workpiece $AC_MEAS_DIR_APPROACH must be set as follows:

$AC_MEAS_TOOL_MASK = 0x80 + 0x200 Tool position in -y direction + tool length
differential values are included negatively

For both tools

Extended Functions
M5: Measurement
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$AC_MEAS_TOOL_MASK = 0x80 + 0x200 Tool position in -y direction + tool length
For both tools

Extended Functions
M5: Measurement
Two milling tools each with their own reference point with tool counter-orientation in the approach
direction
Two milling tools each with their own reference point with a tool orientation in the approach
direction
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Extended Functions
M5: Measurement
Two milling tools each with a reference point with tool counter-orientation in the approach direction
Two milling tools with one reference point with a tool position opposite to the orientation
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$AC_MEAS_TOOL_MASK = 0x2 + 0x200 Tool position in x direction (G19) + tool length

For both tools

Extended Functions
M5: Measurement
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$AC_MEAS_TOOL_MASK = 0x40 + 0x200 Tool position in -x direction + tool length
For both tools

Extended Functions
M5: Measurement
Different tools in the WCS
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Figure 7-22 Two turning tools each with their own reference point

$AC_MEAS_TOOL_MASK = 0x0 All tool lengths are considered
(default setting)

$AC_MEAS_TOOL_MASK = 0x0 All tool lengths are considered
(default setting)
For both tools

$AC_MEAS_Px_COORD = 0 Coordinate system of x-th measuring point =
WCS (default setting)
$AC_MEAS_SET_COORD = 0 Coordinate system of the setpoint =
Extended Functions
M5: Measurement
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Extended Functions
M5: Measurement

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Extended Functions
M5: Measurement
7.6 Measurement accuracy and functional testing
7.6.1 Measurement accuracy

The measuring accuracy is affected by the following parameters:
Delay time of the measuring signal (TDelay)
Traversal speed during the measurement (vM)
Delay time compensation of the measuring signal (TDelay)

The delay time of the measuring signal, i.e. the time from the initiation of the probe until the
saving of the measured value in the control depends on the response time of the probe and
the signal runtime of the control hardware. The control compensates for the delay time
during the measurement. This requires that the delay time is determined and entered in the
MD13220 $MN_MEAS_PROBE_DELAY_TIME = <determined delay time>
Note
Maximum compensated delay time TMaxDelay
TMaxDelay = 15 * position controller or DP cycle
The compensation of a delay time > TMaxDelay is not sensible from the control viewpoint. This
means larger values are limited to TMaxDelay.
Maximum traversal speed during the measurement (vM)

The maximum permitted traversal speed for a measurement depends on the number of
programmed measuring edges and the parameterized position-controller or DP cycle.
To receive correct results, the traversal speed during the measurement must be chosen so
that the following conditions are satisfied every two position-controller or DP cycles:
Maximum one identical trigger signal, i.e. one positive or one negative edge of one probe
Maximum four different identical trigger signals, i.e. one positive and one negative edge
of two probes
Extended Functions
M5: Measurement
7.6.2 Probe function test
Example of function test
Table 7- 7

%_N_PRUEF_MESSTASTER_MPF
;$PATH=/_N_MPF_DIR
;Testing program probe connection
N05 DEF INT MTSIGNAL ;Flag for trigger status
N10 DEF INT ME_NR=1 ; measurement input number
N20 DEF REAL MESSWERT_IN_X
N30 G17 T1 D1 ; tool compensation for
; preselect probe
N40 _ANF: G0 G90 X0 F150 ; Starting position and
; measuring velocity
N50 MEAS=ME_NR G1 X100 ; measurement at measurement input =1
; in the X axis
N60 STOPRE
N70 MTSIGNAL=$AC_MEA[1] ; read software switching signal
; at 1st measurement input
N80 IF MTSIGNAL == 0 GOTOF _FEHL1 ; evaluation of signal
N90 MESSWERT_IN_X=$AA_MW[X] ; Read in measured value of
; workpiece coordinates
N95 M0
N100 M02
N110 _FEHL1: MSG ("Probe not switching!")
N120 M0
N130 M02
Extended Functions
M5: Measurement
7.7 Simulated measuring
Brief description
To make measurements at real machines, probes must be connected which supply
switching signals at certain positions. Probes are not used when making measurements in
simulated environments - the switching positions are specified in a different way.
Simulated measuring supports two ways of entering switching positions:
Position-related switch request: The switching position is derived from the axial end
position programmed in the measuring block.
External switching request: The switching position is defined by controlling a digital
output.
Preconditions
For simulated measuring, all of the machine axes in the system must be parameterized as
simulated axes:
MD30130 $MA_CTRLOUT_TYPE[axis] = 0 (simulated setpoint)
MD30240 $MA_ENC_TYPE[axis] = 0 (simulated encoder)
7.7.2 Position-related switch request
Function
"Position-related switch request" is selected using the following NCK-specific machine data:
MD13230 $MN_MEAS_PROBE_SOURCE = 0
MD13231 $MN_MEAS_PROBE_OFFSET = <position offset>
The axial switching position is calculated from the axial end position programmed in the
measuring block and the parameterized position offset:
Switching position[axis] = End position[axis] - position offset
During the measuring block, it is cyclically checked as to whether the switching position of
the axis is reached:
Setpoint position[axis] switching position[axis]
When the switching position is reached, the rising edge of the switching signal is generated
for probes 1 and 2. One position controller cycle later, the following edges.
Extended Functions
M5: Measurement
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Figure 7-25 Position-dependent switch request
The measured value is the actual value of the axis at the instant in time that the switching
signal programmed in the measuring block occurs (rising / falling edge).
If several axes are programmed in a measuring block, then a dedicated switching position is
obtained for each axis by the position offset that is axially taken into consideration. The
probe signal is generated at the first axial switching position that is reached.
Note
Probe signals
The probe signals are always simultaneously generated for probes 1 and 2.
Negative offset values
The switching position is shifted behind the end position by entering a negative value for the
position offset. In this case, no probe signals are generated.
Examples
The position offset is set to 0.1 mm: MD13231 $MN_MEAS_PROBE_OFFSET = 0.1
Example 1: Channel-specific measuring in 2 axes

N10 G01 G90
N20 MEAS=1 X100 Y10 F100 ; rising edge, probe 1
; Switching position[X] = 99.9
; Switching position[Y] = 9.9
Example 2: Axial measuring using synchronized action

N10 G01 G90
N15 WHEN TRUE DO MEASA[X]=(1,1) ; rising edge, probe 1
N20 X10 F100 ; Switching position[X] = 9.9
Extended Functions
M5: Measurement
7.7.3 External switch request
Function
The "external switching request" is selected using the NCK specific machine data by
entering the number (1...8) of the digital output being used:
MD13230 $MN_MEAS_PROBE_SOURCE = <number of the digital output>
The probe signal is triggered by controlling the configured digital output. It is not necessary
to hard-wire the digital output to a measuring input.
The rising edge of the switching signal for probes 1 and 2 is generated by setting the digital
output. The falling edges are generated by resetting the digital output.
The measured value is the actual value of the axis at the instant in time that the switching
signal programmed in the measuring block occurs (rising / falling edge).
Digital output: Configuration

The following machine data must be set to be able to use digital outputs for simulated
measuring:
MD10360 $MN_FASTIO_DIG_NUM_OUTPUTS = 1 (number of active digital NCK output
bytes)
MD13120 $MN_CONTROL_UNIT_LOGIC_ADDRESS = 0 (logical address, SINAMICS-
CU)
Digital output: Setting

The configured digital output can be set in a synchronized action:
WHEN <condition> DO $A_OUT[<number of digital output>] = 1
Examples
Digital output used: MD13230 $MN_MEAS_PROBE_SOURCE = 1
Example 1: Channel-specific measuring in 2 axes

N10 G01 G90 $A_OUT[1]=0 ; Preset digital output 1
N15 WHEN $AC_DETW<=10 DO $A_OUT[1]=1 ; Path residual distance <= 10 => Dig. output 1 = 1
N20 MEAS=1 X100 Y10 F100 ; rising edge, probe 1
Example 2: Axial measurement

N10 G01 G90 $A_OUT[1]=0 ; Preset digital output 1
N15 WHEN $AA_IW[X]>=80 DO $A_OUT[1]=1 ; Axial setpoint >= 80 => Dig. output 1 = 1
N20 MEASA[X]=(1,1) X100 F100 ; rising edge, probe 1
Extended Functions
M5: Measurement
7.7.4 System variable

For simulated measuring, the following system variables have the same functionality as for
real measuring:
$AC_MEA (probe has responded)
$AA_MEAACT (axial measuring active)
$AA_MM (acquired probe position (MCS))
$AA_MM1...4 (probe position 1st 4th trigger (MCS))
$AA_MW (acquired probe position (WCS))
$AA_MW1...4 (probe position 1st trigger (WCS))
The following system variable does not supply sensible values:
$A_PROBE (probe state)
7.8.1 Measuring mode 1

One-time measurement
One probe
Trigger signals are the rising and falling edges
Measurement with one encoder - actual value for the current encoder
Program code
N2 MEASA[X] = (1, 1, -1) G01 X100 F100
N3 STOPRE
N4 IF $AC_MEA[1]==FALSE gotof ENDE
N5 R10=$AA_MM1[X]
N6 R11=$AA_MM2[X]
N7 END
Extended Functions
M5: Measurement
Measurement with two encoders - actual values for two encoders
Program code
N2 MEASA[X] = (31, 1, -1) G01 X100 F100
N3 STOPRE
N5 R10=$AA_MM1[X]
N6 R11=$AA_MM2[X]
N7 R12=$AA_MM3[X]
N8 R13=$AA_MM4[X]
N9 END
7.8.2 Measuring mode 2

Two probes
Trigger signals are the rising and falling edges
Actual value from the current encoder
Program code
N2 MEASA[X] = (2, 1, -1, 2, -2) G01 X100 F100
N3 STOPRE
N4 IF $AC_MEA[1]==FALSE gotof MESSTASTER2
N5 R10=$AA_MM1[X]
N6 R11=$AA_MM2[X]
N7 PROBE2
N9 R12=$AA_MM3[X]
N10 R13=$AA_MM4[X]
N11 END:
7.8.3 Continuous measurement

The measurement is done in measuring mode 1:
Measurement with 100 values
One probe
Trigger signal is the falling edge
Actual value from the current encoder
Extended Functions
M5: Measurement
Continuous measurement on completion of programmed traversing movement

N1 DEF REAL MESSWERT[100]
N2 DEF INT INDEX=0
N3 MEAC[x]=(1, 1, -1) G01 X1000 F100
N4 MEAC[X]=(0) ; Abort
N5 R1=$AC_FIFO1[4] ;Number of measured values
N6 FOR INDEX=0 TO R1
N7 MESSWERT[INDEX]=$AC_FIFO1[0] ; Read out measured values
N8 ENDFOR:
Continuous measurement with deletion of distance-to-go

Delete distance-to-go after last measurement.

N1 DEF INT ANZAHL=100
N2 DEF REAL MESSWERT[ANZAHL]
N3 DEF INT INDEX=0
N4 WHEN $AC_FIFO1[4]==ANZAHL DO DELDTG (X) MEAC[X] =(0)
N5 MEAC[X]=(1, 1, -1) G01 X1000 F100 ; Start measurement
N6 R1=$AC_FIFO1[4] ;Number of measured
values
N8 MESSWERT[INDEX]=$AC_FIFO1[0] ; Read out measured
values
N9 ENDFOR:
Continuous modal measurement over several blocks

N1 DEF INT ANZAHL=100
N2 DEF REAL MESSWERT[ANZAHL]
N3 DEF INT INDEX=0
N4 ID=1 MEAC[X]=(1, 1, -1) ; Start measurement
N5 ID=2 WHEN $AC_FIFO1[4]==ANZAHL DO MEAC[X]=(0)
CANCEL(2)
N6 G01 X1000 Y100
N7 X100 Y100
N8 R1=$AC_FIFO1[4] ;Number of measured
values
N10 MESSWERT[INDEX]=$AC_FIFO1[0] ; Read out measured
values
N11 ENDFOR:
Extended Functions
M5: Measurement
7.8.4 Functional test and repeat accuracy
Function test

%_N_PRUEF_MESSTASTER_MPF
;$PATH=/_N_MPF_DIR
;Testing program probe connection
N05 DEF INT MTSIGNAL ;Flag for trigger status
N10 DEF INT ME_NR=1 ; measurement input number
N20 DEF REAL MESSWERT_IN_X
N30 G17 T1 D1 ; tool compensation for
; preselect probe
N40 _ANF: G0 G90 X0 F150 ; Starting position and
; measuring velocity
N50 MEAS=ME_NR G1 X100 ; measurement at measurement input =1
; in the X axis
N60 STOPRE
N70 MTSIGNAL=$AC_MEA[1] ; read software switching signal
; at 1st measurement input
N80 IF MTSIGNAL == 0 GOTOF _FEHL1 ; evaluation of signal
N90 MESSWERT_IN_X=$AA_MW[X] ; Read in measured value of
; workpiece coordinates
N95 M0
N100 M02
N110 _FEHL1: MSG ("Probe not switching!")
N120 M0
N130 M02
Repeat accuracy
This program allows the measuring scatter (repeat accuracy) of the entire measuring system
(machine-probe-signal transmission to NC) to be calculated.
In the example, ten measurements are taken in the X axis and the measured value recorded
in the workpiece coordinates.
It is therefore possible to determine the random dimensional deviations which are not subject
to any trend.

%_N_PRUEF_GENAU_MPF;
$PATH=/_N_MPF_DIR
N05 DEF INT SIGNAL, II ; Variable definition
Extended Functions
M5: Measurement
7.9 Data lists

N10 DEF REAL MESSWERT_IN_X[10]
N15 G17 T1 D1 ; Initial conditions,
: Tool compensation
; preselect for probe
N20 _ANF: G0 X0 F150 ; Prepositioning in the measured axis
N25 MEAS=+1 G1 X100 ; at 1st measurement input when
; switching signal not deflected,
; deflected in the X axis
N30 STOPRE ; Stop decoding for this after
; subsequent evaluation of
; results
N35 SIGNAL= $AC_MEA[1] ; read software switching signal at
; 1. Read measuring input
N37 IF SIGNAL == 0 GOTOF_FEHL1 ; Check switching signal
N40 MESSWERT_IN_X[II]=$AA_MW[X] ; Read measured value in workpiece
coordinates
N50 II=II+1
N60 IF II<10 GOTOB_ANF ; Repeat 10 times
N65 M0
N70 M02
N80 _FEHL1: MSG ("Probe not switching")
N90 M0
N95 M02
After the parameter display (user-defined variables) has been selected, the measurement
results can be read in field MEASVALUE_IN_X[10] provided that the program is still being
processed.
7.9 Data lists
7.9.1 Machine data
Number Identifier: $MN_ Meaning

13200 MEAS_PROBE_LOW_ACTIVE Switching characteristics of probe
13201 MEAS_PROBE_SOURCE Measuring pulse simulation via digital output
13210 MEAS_TYPE Type of measurement for PROFIBUS DP drives
13211 MEAS_CENTRAL_SOURCE Central measuring data source with PROFIBUS DP
drives
Extended Functions
M5: Measurement
7.9 Data lists
Number Identifier: $MC_ Meaning

20360 TOOL_PARAMETER_DEF_MASK Definition of tool parameters
28264 LEN_AC_FIFO Length of $AC_FIFO ... FIFO variables
Table of all the input values
Identifier Meaning
$AC_FIFO110 FIFO variable 1 to 10
$AC_MEAS_SEMA Interface assignment
$AC_MEAS_VALID Validity bits for input values
$AA_MEAS_POINT1 1. Measuring point for all channel axes
$AA_MEAS_SETPOINT Setpoint position for all channel axes
$AA_MEAS_SETANGLE Setpoint angle for all channel axes
$AC_MEAS_P1_COORD Coord. system for the 1st measuring point
$AC_MEAS_P2_COORD Coord. system for the 2nd measuring point
$AC_MEAS_P3_COORD Coord. system for the 3rd measuring point
$AC_MEAS_P4_COORD Coord. system for the 4th measuring point
$AC_MEAS_SET_COORD Coordinate system of the setpoint
$AC_MEAS_LATCH[0...3] Pick up measuring points in the WCS
$AA_MEAS_P1_VALID 1. Pick up measuring point in the WCS
$AA_MEAS_SP_VALID Set setpoint position of axis as valid
$AC_MEAS_WP_SETANGLE Setpoint workpiece position angle
$AC_MEAS_CORNER_SETANGLE Setpoint cutting angle of corner
$AC_MEAS_DIR_APPROACH Approach direction
$AC_MEAS_ACT_PLANE Working plane for the workpiece
$AC_MEAS_SCALEUNIT Unit of measurement INCH / METRIC
$AC_MEAS_FINE_TRANS Corrections in fine displacement
$AC_MEAS_FRAME_SELECT Frame selection for the workpiece measurement
Extended Functions
M5: Measurement
7.9 Data lists
Identifier Meaning
$AC_MEAS_CHSFR Frame chain setting: System frames
$AC_MEAS_NCBFR Frame chain setting: Global basic frames
$AC_MEAS_CHBFR Frame chain setting: Channel basic frames
$AC_MEAS_UIFR Frame chain setting: Settable frames
$AC_MEAS_PFRAME Frame chain setting: Program frame
$AC_MEAS_T_NUMBER Tool selection
$AC_MEAS_D_NUMBER Cutting edge selection
$AC_MEAS_TOOL_MASK Tool settings
$AC_MEAS_TYPE Measuring type
$AC_MEAS_INPUT Measurement input parameters
Table of all the output values
Identifier Meaning
$A_PROBE[1,2] Probe status
$A_PROBE_LIMITED[1,2] Measuring velocity exceeded
$AC_MEA[1,2] Probe has responded
$AA_MM Acquired probe position (MCS)
$AA_MM1...4 Probe position 1st to 4th trigger event (MCS)
$AA_MW Acquired probe position (WCS)
$AA_MW1...4 Probe position 1st to 4th trigger event (WCS)
$AC_MEAS_FRAME Result frame
$AC_MEAS_CORNER_ANGLE Calculated angle of intersection
$AC_MEAS_DIAMETER Calculated diameter
$AC_MEAS_TOOL_LENGTH Calculated tool length
$AC_MEAS_RESULTS Measurement results (depending on measurement type)
Extended Functions
N3: Software cams, position switching cycles - only
840D sl 8
8.1 Brief Description
Function
The "Software cams" function generates position-dependent switching signals for axes that
supply an actual position value (machine axes) and for simulated axes.
These cam signals can be output to the PLC and also to the NCK I/Os.
The cam positions at which signal outputs are set can be defined and altered via setting
data. The setting data can be read and written via HMI, PLC and part program.
Activation
The "Software cams" function can be activated and used in all operating modes. The
function remains active in the event of reset or Emergency Stop.
Field of application
Output cam signals can be used, for example:
To activate protection zones
To initiate additional movements as a function of position
As reversing signals for hydraulically controlled oscillation axes
Axis types
Software cams can be used on linear and modulo rotary axes that are defined as machine
axes.
Cam range/cam pair

Cams are always assigned in pairs to axes. A pair consists of a plus and a minus cam. 32
cam pairs are available.
The plus and minus cams each simulate a mechanical cam which is actuated at a defined
point (cam position) in a specific approach direction when the axis reaches the cam position.
Cam ranges are assigned to the plus and minus cams as follows:
Cam range plus: All positions plus cam

Cam range minus: All positions minus cam
Extended Functions
N3: Software cams, position switching cycles - only 840D sl
8.2 Cam signals and cam positions
8.2.1 Generation of cam signals for separate output

Separate output of the plus and minus cam signals makes it easy to detect whether the axis
is within or outside the plus or minus cam range.
Linear axes
The switching edges of the cam signals are generated as a function of the axis traversing
direction:
The minus cam signal switches from 1 to 0 when the axis traverses the minus cam in the
positive axis direction.
The plus cam signal switches from 0 to 1 when the axis traverses the plus cam in the
positive direction.
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Figure 8-1 Software cams for linear axis (minus cam < plus cam)
Note
If the axis is positioned exactly at the output cam position (plus or minus), the defined
output flickers. If the axis moves one increment further, the output becomes a definite
zero or one.
Flickering of the actual position causes the signals to flicker in this manner.
The actual position is evaluated.
Extended Functions
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Figure 8-2 Software cams for linear axis (plus cam < minus cam)
Modulo rotary axes

The switching edges of the cam signals are generated as a function of the rotary axis
traversing direction:
The plus cam signal switches from 0 to 1 when the axis traverses the minus cam in a
positive axis direction and from 1 back to 0 when it traverses the plus cam.
The minus cam signal changes level in response to every positive edge of the plus cam
signal.
Note
The described response of the plus cam applies on conditionthat:
plus cam - minus cam < 180 degrees
Extended Functions
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Figure 8-3 Software cams for modulo rotary axis (plus cam - minus cam < 180 degrees)
The signal change of the minus cam makes it possible to detect traversal of the cam even if
the cam range is set so small that the PLC cannot detect it reliably.
Both cam signals can be output to the PLC and to the NCK I/Os. Separate output of the plus
and minus cam signals makes it easy to detect whether the axis is within or outside the plus
or minus cam range.
If this condition (plus cam - minus cam < 180 degrees) is not fulfilled or if the minus cam is
set to a greater value than the plus cam, then the response of the plus cam signal is
inverted. The response of the minus cam signal remains unchanged.
Extended Functions
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Figure 8-4 Software cams for modulo rotary axis (plus cam - minus cam > 180 degrees)
8.2.2 Generation of cam signals with gated output

The plus and minus cam output signals are gated in the case of:
timer-controlled cam signal output to the four onboard outputs on the NCU
Output to the NCK I/O, if the 2nd byte in the following machine data was not specified (=
"0"):
MD10470 SW_CAM_ASSIGN_FASTOUT_2
...
MD10473 SW_CAM_ASSIGN_FASTOUT_4
Extended Functions
Linear axes
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Figure 8-6 Position switching signals for linear axis (plus cam < minus cam)
Extended Functions
Modulo rotary axis

The default signal response for modulo rotary axes is dependent on the cam width:
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Figure 8-7 Software cams for modulo rotary axis (plus cam - minus cam < 180 degrees)
Extended Functions
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Figure 8-8 Software cams for modulo rotary axis (plus cam - minus cam > 180 degrees)
Extended Functions
Suppression of signal inversion

With the following setting, selection of signal inversion for
"plus cam - minus cam > 180 degrees" can be suppressed.
MD10485 SW_CAM_MODE bit 1=1
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Figure 8-9 Software cams for modulo rotary axis (plus cam - minus cam > 180 degrees) and suppression of signal
inversion
8.2.3 Cam positions
Setting cam positions

The positions of the plus and minus cams are defined using general setting data:
SD41500 SW_CAM_MINUS_POS_TAB_1[n] Position of minus cams 1 - 8

SD41501 SW_CAM_PLUS_POS_TAB_1[n] Position of plus cams 1 8
SD41503 SW_CAM_PLUS_POS_TAB_2[n] Position of plus cams 9 - 16
Extended Functions

Note
Owing to the grouping of cam pairs (eight in each group), it is possible to assign different
access authorization levels (e.g. for machine-related and workpiece-related cam positions).
The positions are entered in the machine coordinate system. No check is made with respect
to the maximum traversing range.
Dimension system metric/inch

With the setting:
MD10260 CONVERT_SCALING_SYSTEM = 1
, the cam positions no longer refer to the configured basic dimension system, but to the
dimension system set in the following machine data:
MD10270 POS_TAB_SCALING_SYSTEM (measuring system of position tables)
Value Meaning
0 Metric
1 inch
MD10270 therefore defines the dimension system for position data from setting data
SD41500 SD41507.
A switchover with G70/G71 or G700/G710 has no effect.
Sensing of cam positions

To set the cam signals, the actual position of the axes is compared to the cam position.
Writing/reading of cam positions

The setting data can be read and written via HMI, PLC and part program.
Accesses from the part program are not synchronous to machining.
Synchronization can only be achieved by means of a programmed block preprocessing stop
(STOPRE command).
It is possible to read and write the cam positions with FB2 and FB3 in the PLC user program.
Extended Functions
Axis/cam assignment
A cam pair is assigned to a machine axis using the general machine data:
MD10450 SW_CAM_ASSIGN_TAB[n] (assignment of software cams to machine axes)
Note
Changes to an axis assignment take effect after the next NCK power-up.
Cam pairs to which no axis is assigned are not active.
A cam pair can only be assigned to one machine axis at a time.
Several cam pairs can be defined for one machine axis.
8.2.4 Lead/delay times (dynamic cam)
Function
To compensate for any delays, it is possible to assign two lead or delay times with additive
action to each minus and plus cam for the cam signal output.
The two lead or delay times are entered in a machine data and a setting data.
Note
The input of negative time values causes a delay in the output of cam signals.
Lead or delay time in machine data

The first lead or delay time is entered in the following general machine data:
MD10460 SW_CAM_MINUS_LEAD_TIME[n] (lead or delay time at the minus

cams)
MD10461 SW_CAM_PLUS_LEAD_TIME[n] (lead or delay time at the plus
cams)
For example, the following can be entered into the machine data:
Constant internal delay times between actual value sensing and cam signal output (e.g.
as determined by an oscilloscope)
Constant external delay times
Extended Functions
8.3 Output of cam signals
Lead or delay time in setting data

The second lead or delay time is entered into the following general setting data:
SD41520 SW_CAM_MINUS_TIME_TAB_1[n] (lead or delay time at the minus

cams 1 8)
SD41521 SW_CAM_PLUS_TIME_TAB_1[n] (lead or delay time at the plus
cams 1 8)
cams 9 16)
cams 9 16)
cams 17 24)
SD41525 SW_CAM_PLUS_TIME_TAB_3[n] Lead or delay time on plus cams
17 - 24
cams 25 32)
cams 25 32)
Delay times which may change during machining must, for example, be entered in the
setting data.
8.3.1 Activating
The status of the cam (cam signals) can be output to the PLC as well as to the NCK I/Os.
Activation of cam signal output

The output of cam signals of an axis is activated via the NC/PLC interface signal:
DB31, ... DBX2.0 (cam activation)
Check-back signal to PLC

The successful activation of all cams of an axis is signaled back to the PLC using the
following NC/PLC interface signal:
DB31, ... DBX62.0 (cams active)
Note
The activation can be linked with other conditions by the PLC user (e.g. axis referenced,
reset active).
Extended Functions
8.3.2 Output of cam signals to PLC
Output to PLC
The status of the cam signals for all machine axes with activated software cams is output to
the PLC.
The status is output in the IPO cycle and is transferred to the PLC asynchronously.
Minus cam signals

The status of the minus cam signals is entered into the following NC/PLC interface signals:
DB10 DBX110.0 to 113.7 (minus cam signal 1 to 32)
Plus cam signals

The status of the plus cam signals is entered into the following NC/PLC interface signals:
DB10 DBX114.0 to 117.7 (plus cam signals 1 to 32)
Note
If no measuring system has been selected or NC/PLC interface signal DB31, ... DBX2.0
(cam activation) is set to 0, then the following NC/PLC interface signals are also set to 0:
DB10 DBX110.0-113.7 (minus cam signals 1-32)
DB10 DBX114.0-117.7 (plus cam signals 1-32)
DB31, ... DBX62.0 (cams active)
8.3.3 Output of cam signals to NCK I/Os in position control cycle
Signal output in position control cycle

For cams assigned to an HW byte via machine data MD10470 to MD10473 (see Section
"Hardware assignment"), the signal is output in the position control cycle.
The four onboard outputs on the NCU and a total of 32 optional external NCK outputs are
available as the digital outputs of the NCK I/Os (see Section "A4: Digital and analog NCK
I/Os for SINUMERIK 840D sl (Page 25)").
Extended Functions
Hardware assignment
The assignment to the hardware bytes used is made for each eight cam pairs in the following
general machine data:
MD10470 SW_CAM_ASSIGN_FASTOUT_1 Hardware assignment for output of cams

1 - 8 to NCK I/Os
9 - 16 to NCK I/Os
17 - 24 to NCK I/Os
25 - 32 to NCK I/Os
Note
It is possible to define one HW byte for the output of eight minus cam signals and one HW
byte for the output of eight plus cam signals in each machine data.
In addition, the output of the cam signals can be inverted with the two machine data.
If the 2nd byte is not specified (= "0"), then the 8 cams are output as a logic operation of the
minus and plus cam signals via the 1st HW byte using the 1st inversion screen form.
Status query in the part program

The status of the HW outputs can be read in the part program with main run variable
$A_OUT[n] (n = no. of output bit).
Switching accuracy
Signals are output to the NCK I/Os or onboard outputs in the position control cycle.
As a result of the time scale of the position control cycle, the switching accuracy of the cam
signals is limited as a function of the velocity.
The following applies:
Delta pos = Vact * position control cycle
with: Delta pos = switching accuracy (depending on position control cycle)

Vact = Current axis velocity
Example:
Vact = 20 m/min, PC cycle = 4 ms Delta pos = 1.33 mm

Vact = 2000 rpm, PC cycle = 2 ms Delta pos = 24 degrees
Extended Functions
8.3.4 Timer-controlled cam signal output
Timer-controlled output
A significantly higher degree of accuracy can be achieved by outputting the cam signals
independently of the position control cycle using a timer interrupt.
The following machine data can be used to select the timer-controlled output to the 4 NCU
onboard outputs for 4 cam pairs:
MD10480 SW_CAM_TIMER_FASTOUT_MASK (screen form for the output of cam signals
via timer interrupts on the NCU)
In this case, the minus and plus signals of a cam pair are logically combined for output as
one signal.
Signal generation
Previously, it had to be specified in which way the signals to be logically combined should be
generated. This is realized using bit 1 in machine data:
MD10485 SW_CAM_MODE (behavior of the software cams)
Bit Value Signal generation

1 0 Inversion of the signal behavior of the plus cam when:
plus cam - minus cam 180 degrees
1 No inversion of the signal behavior of the plus cam when:
Note
This function operates independently of the HW assignment selected in
MD10470 ... MD10473.
The onboard byte may not be used a multiple number of times.
Restrictions
The following applies to the mutual position of the cam positions:
Only one timer-controlled output takes place per interpolation cycle.
If signal changes for more than one cam pair are active in the same interpolation cycle, the
output is prioritized:
The cam pair with the lowest number (1...32) determines the output time for all active
signals, i.e. the signal change of the other cam pairs takes place at the same time.
Extended Functions
PLC interface
The NCK image of the onboard outputs and the status of the plus and minus cams is
displayed on the PLC interface.
However, these signals are irrelevant or correspondingly inaccurate for the timer-controlled
cam output version, as described in the following paragraphs. The signals for the plus and
minus cams are generated (once) in synchronism with the interpolation cycle and transmitted
together to the PLC.
Pulses shorter than an interpolation cycle are thus imperceptible on the PLC.
The onboard outputs are set and reset asynchronously to the interpolation cycle for each
interrupt. The status of the onboard outputs is detected and transmitted to the PLC in
synchronism with the update time of the PLC interface.
Depending on the current status at the moment the PLC interface is updated, pulses shorter
than one interpolation cycle are not visible or are displayed stretched by one or several IPO
cycles.
Further settings
The following bit must be set to "0" if the behavior described here is to be activated:
MD10485 SW_CAM_MODE bit 0 = 0
8.3.5 Independent, timer-controlled output of cam signals
Independent, timer-controlled cam output

Each switching edge is output separately per interrupt due to the timer-controlled,
independent (of interpolation cycle) cam output.
The mutual influence of the cam signals is no longer applicable as a result of:
single output per interpolation cycle
output time determined by highest priority cam pair (lowest cam pair number)
A total of 8 timer-controlled cam outputs per interpolation cycle can be configured for
setting/resetting the four onboard outputs. The signal states of the plus and minus cams are
also made available as standard on the PLC interface for the timer-controlled variant,
However, these signals are not relevant or are correspondingly inaccurate with a timer-
controlled output.
Extended Functions
8.4 Position-time cams
Signal generation
Previously, it had to be specified in which way the signals to be logically combined should be
generated. This is realized using bit 1 in machine data:
MD10485 SW_CAM_MODE (behavior of the software cams)
Bit Value Signal generation

1 0 Inversion of the signal behavior of the plus cam when:
1 No inversion of the signal behavior of the plus cam when:
Settings
Cam pairs are assigned to onboard outputs using machine data:
MD10480 SW_CAM_TIMER_FASTOUT_MASK (screen form for the output of cam signals
via timer interrupts on the NCU)
In addition, this type of processing must be explicitly selected:
MD10485 SW_CAM_MODE bit 0 = 1
Note
This function operates independently of the HW assignment selected in
MD10470 MD10473.
The onboard byte may not be used a multiple number of times.
Position-time cams
The term "position-time cam" refers to a pair of software cams that can supply a pulse of a
certain duration at a defined axis position.
Solution
The position is defined by a pair of software cams.
The pulse duration is defined by the lead/delay time of the plus cam.
Machine data can be used to specify that cam pairs with "minus cam position = plus cam
position" should be processed as position-time cams.
Extended Functions
Properties of position-time cams

The pulse duration is independent of the axis velocity and travel direction reversal.
The pulse duration is independent of changes in the axis position (Preset).
Activation (rising signal edge) takes place only when the cam position is crossed.
Moving the axis position (e.g. preset) does not trigger activation.
A lead/delay time is operative for the minus cam and causes a time displacement of the
pulse.
Activation (ON edge) and pulse duration are independent of the travel direction.
The cam is not deactivated if the cam position is crossed again when the cam is active
(direction reversal).
The cam time (pulse width) is not interrupted and the cam time not restarted when the
cam position is crossed again.
This behavior is particularly relevant with respect to modulo axes, i.e. if the cam time is
greater than the modulo range crossing time, the cam is not switched in every revolution.
Settings
The following settings must be made to program a position-time cam:
Position
The position must be defined by a cam pair with which the minus cam position is equal to
the plus cam position.
This is defined using setting data:
SD41500 SW_CAM_MINUS_POS_TAB_1
...
SD41507 SW_CAM_PLUS_POS_TAB_4.
Pulse duration
The pulse duration is calculated by adding together the associated entries for the cam
pair in:
MD10461 SW_CAM_PLUS_LEAD_TIME[n]
SD41521 SW_CAM_PLUS_TIME_TAB_1[n]...
SD41527 SW_CAM_PLUS_TIME_TAB_4[n]
Offset
The time displacement of the position-time cam is calculated by adding together the
associated entries for the cam pair in:
MD10460 SW_CAM_MINUS_LEAD_TIME[n]
SD41520 SW_CAM_MINUS_TIME_TAB_1[n]...
SD41526 SW_CAM_MINUS_TIME_TAB_4[n]
Mode
MD10485 SW_CAM_MODE
Bit 2 = 1 must be set in the machine data to ensure that all cam pairs with the same
values for minus cam and plus cam positions are treated as position-time cams.
Extended Functions
8.5 Supplementary Conditions
Availability of function "Software cams, position switching signals"

The function is an option ("position-switching signals/cam controller"), which must be
assigned to the hardware through the license management.
8.6 Data lists
8.6.1 Machine data

10260 CONVERT_SCALING_SYSTEM Basic system switchover active
10270 POS_TAB_SCALING_SYSTEM System of measurement of position tables
10450 SW_CAM_ASSIGN_TAB[n] Assignment of software cams to machine axes
10460 SW_CAM_MINUS_LEAD_TIME[n] Lead or delay time on minus cams 1 -16
10461 SW_CAM_PLUS_LEAD_TIME[n] Lead or delay time on plus cams 1 -16
10470 SW_CAM_ASSIGN_FASTOUT_1 Hardware assignment for output of cams
1 -8 to NCK I/Os
9 -16 to NCK I/Os
17 -24 to NCK I/Os
25 -32 to NCK I/Os
10480 SW_CAM_TIMER_FASTOUT_MASK Screen form for output of cam signals via timer
interrupts to NCU
10485 SW_CAM_MODE Response of SW cams
Extended Functions
8.6 Data lists
8.6.2 Setting data

41500 SW_CAM_MINUS_POS_TAB_1[n] Position of minus cams 1 -8
41501 SW_CAM_PLUS_POS_TAB_1[n] Position of plus cams 1 -8
41520 SW_CAM_MINUS_TIME_TAB_1[n] Lead or delay time on minus cams 1 -8
41521 SW_CAM_PLUS_TIME_TAB_1[n] Lead or delay time on plus cams 1 -8
8.6.3 Signals

Cam activation DB31, ... .DBX2.0 -

Cams active DB31, ... .DBX62.0 -
Extended Functions
N4: Own channel - only 840D sl 9
Subfunctions
The functions specific to punching and nibbling operations comprise the following:
Stroke control
Automatic path segmentation
Rotatable punch and die
Clamp protection
They are activated and deactivated via language commands.
9.2 Stroke control
Functionality
The stroke control is used in the actual machining of the workpiece. The punch is activated
via an NC output signal when the position is reached. The punching unit acknowledges its
punching motion with an input signal to the NC. No axis may move within this time period.
Repositioning takes place after the punching operation.
High-speed signals
"High-speed signals" are used for direct communication between the NC and punching unit.
Combined with the punch, they allow a large number of holes to be punched per minute
since the punch positioning times are interpreted as machining delays.
PLC signals
PLC interface signals are used for non-time-critical functions such as enabling and
monitoring.
Extended Functions
N4: Own channel - only 840D sl
9.2 Stroke control
9.2.2 High-speed signals
Functionality
High-speed signals are used to synchronize the NC and punching unit. On the one hand,
they are applied via a high-speed output to ensure that the punch stroke is not initiated until
the metal sheet is stationary. On the other, they are applied via a high-speed input to ensure
that the sheet remains stationary while the punch is active.
The high-speed digital inputs and outputs on the control are used to drive the punching unit.
The following signal chart illustrates the signal sequence.

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(b) "Stroke initiation" signal
(c) "Stroke active" signal
Figure 9-1 Signal chart
Note
The "Stroke active" signal is high-active for reasons relating to open-circuit monitoring.
Extended Functions
9.2 Stroke control
The chronological sequence of events for punching and nibbling is controlled by the two
signals A0 and E0:
A0 Set by the NCK and identical to stroke initiation.

E0 Defines the status of the punching unit and identical to the "Stroke active" signal.
The signal states characterize and define times t1 to t4 in the following way:
t1 The motion of the workpiece (metal sheet) in relation to the punch is completed at instant t1.
Depending on the criterion defined for stroke initiation (see Section "Criteria for stroke initiation
(Page 558)"), the high-speed output A0 is set for punch initiation .
t2 The punching unit signals a punch movement via high-speed input E0 at instant t2.
This is triggered by signal A0 .
For safety reasons, signal E0 is high-active (in the case of an open circuit, "Stroke active" is
always set and the axes do not move).
The "Stroke active" signal is not reset again until the tool has moved away from the metal
sheet (t4).
t3 The NC reacts to the "Stroke active" signal at instant t3 by canceling the "Stroke initiation"
signal . From this point in time onwards, the NC is in a waiting state. It simply waits for
cancellation of the "Stroke active" signal so it can initiate the next axis motion.
The next stroke can be initiated only after signal A0 has disappeared.
t4 The punching operation is complete at instant t4, i.e. the punch has exited from the metal sheet
again.
The NC reacts to a signal transition in signal E0 by starting an axis motion .
The reaction of the NC to a signal edge change is described in the section headed "Axis
start after punching".
Note
The stroke time is determined by the period th = t4 - t1.
Reaction times at instant t4 between the signal transition of E0 and the start of the axis
motion must also be added.
Extended Functions
9.2 Stroke control
9.2.3 Criteria for stroke initiation
Initiate a stroke
The stroke initiation must be set, at the earliest, for the point in time at which it can be
guaranteed that the axes have reached a standstill. This ensures that at the instant of
punching, there is absolutely no relative movement between the punch and the metal sheet
in the machining plane.
The following diagram shows the various criteria that can be applied to stroke initiation.
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Figure 9-2 Signal chart: Criteria for stroke initiation
The time interval between t1 and t2 is determined by the reaction of the punching unit to
setting of output A0. This cannot be altered, but can be utilized as a lead time for minimizing
dead times.
The diagram above shows the default setting with which the output is set when the "Exact
stop fine window" is reached (G601; default setting of G group 12). The punch initiation times
t''1 and t'1 are programmed by means of G602 and G603 (see table below).
Programming Activation Description

G603 Stop interpolation The interpolation reaches the block end. In this case,
the axes continue to move until the overtravel has
been traversed, i.e. the signal is output at an
appreciable interval before the axes have reached
zero speed (see t"1).
Extended Functions
9.2 Stroke control
Programming Activation Description

G602 Reach the coarse in- The signal is output once the axes have reached the
position window coarse in-position window. If this criterion is selected
for stroke initiation output, then the instant of stroke
initiation can be varied through the size of interpolation
window (see t'1).
G601 Reach the fine in- In this case, it can always be ensured that the machine
position window will have reached a standstill at the instant of punching
provided that the axis data are set appropriately.
However, this variant also results in a maximum dead
time (see t1).
Note
The initial setting of the G group with G601, G602 and G603 (G group 12) is defined via
machine data:
MD20150 $MC_GCODE_RESET_VALUES[11]
The default setting is G601.
G603
Depending on velocity and machine dynamics, approximately 3 - 5 interpolation cycles are
processed at the end of interpolation before the axes reach zero speed.
MD26018 $MC_NIBBLE_PRE_START_TIME
In conjunction with the above machine data, it is possible to delay, and therefore optimize,
the instant between reaching the end of interpolation and setting the high-speed output for
"Stroke ON".
The following setting data is available in addition to MD26018:
SD42402 $SC_NIBPUNCH_PRE_START_TIME
SD42402 can be changed from the part program and therefore adapted to the punching
process depending on the progress of the part program run.
The following applies to the delay time:
MD26018 = 0 SD42402 is operative

MD26018 0 MD26018 is operative
If the "Punching with dwell time, PDELAYON" is active, then the dwell time programmed in
connection with this function is active. Neither MD26018 nor SD42402 is operative in this
case.
Extended Functions
9.2 Stroke control
9.2.4 Axis start after punching
Input signal "Stroke ON"

The start of an axis motion after stroke initiation is controlled via input signal "Stroke ON".
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Figure 9-3 Signal chart: Axis start after punching
In this case, the time interval between t4 and t'4 acts as a switching-time-dependent reaction
time. It is determined by the interpolation sampling time and the programmed
punching/nibbling mode.
PON/SON
When the punching unit is controlled via PON/SON, the maximum delay time is calculated to be:
|t'4 - t4| = 3 x interpolation cycles
PONS/SONS
If the punch is controlled by PONS/SONS, the delay time is determined by:
|t'4 - t4| 3 x position controller cycles
Prerequisites: Stroke time (t4 - t2) > 4 interpolation cycles
Extended Functions
9.2 Stroke control
9.2.5 PLC signals specific to punching and nibbling
Function
In addition to the signals used for direct stroke control, channel-specific PLC interface
signals are also available. These are used both to control the punching process and to
display operational states.
Signals
Signal Activation
DB21, ... DBX3.0 (no stroke enable) Prevents the NC from initiating a punching operation.
The NC waits until the enable signal is available
before continuing the part program.
DB21, ... DBX3.2 (stroke suppression) Allows the part program to be processed without
initiating a punching operation (dry run).
With active path segmentation, the axes traverse in
"Stop and go" mode.
DB21, ... DBX3.4 (delayed stroke) Activates delayed stroke output if permitted by
PDELAYON.
DB21, ... DBX3.1 (manual stroke Enables the operator to initiate a punching operation
suppression) (controlled via the PLC) without executing the part
program.
Manual stroke initiation is acknowledged with signal:
DB21, .. DBX38.1 (acknowledgement of manual
stroke initiation)
9.2.6 Punching and nibbling-specific reactions to standard PLC signals
DB21, ... DBX12.3 (feed stop)

With interface signal:
DB21, ... DBX12.3 (feed stop)
, the NC reacts in the following way with respect to the stroke control:
Signal is detected in advance of instant t1: Stroke initiation is suppressed.

The next stroke is not initiated until the next start or
until the "Feed stop" signal has been canceled.
Machining is then continued as if there had been no
interruption.
Signal is detected at instant t1: The current stroke is executed to completion.
The NC then dwells in the state characterized by t4.
To allow it to respond in this manner, time monitoring
of the "Stroke active" and "Stroke initiation" signals is
dispensed with.
Extended Functions
9.3 Activation and deactivation
9.2.7 Signal monitoring
Oscillating signal
Owing to aging of the punch hydraulics, overshooting of the punch may cause the "Stroke
active" signal to oscillate at the end of a stroke.
In this case, an alarm (22054 "undefined punching signal") can be generated as a function of
machine data:
MD26020 $MC_NIBBLE_SIGNAL_CHECK
.
Reset response
In the case of an NCK reset, the interface signal:
DB21, ... DBX38.0 (stroke initiation active)
is canceled immediately without acknowledgement by the high-speed input.
A currently activated stroke cannot be suppressed.
9.3.1 Language commands

Punching and nibbling functions are activated and deactivated via configurable language
commands. These replace the special M functions that were used in earlier systems.
References:
Programming Manual, Production Planning
Groups
The language commands are subdivided into the following groups:
Group 35
The actual punching and nibbling-specific functions are activated and deactivated by means of the
following language commands:
PON = punching ON
SON = nibbling ON
PONS = punching ON, activated in the position controller
SONS = nibbling ON, activated in the position controller
SPOF = punching/nibbling OFF
Extended Functions
Group 36
This group includes the commands which have only a preparatory character and which determine the
real nature of the punching function:
PDELAYON = punching with delay ON
PDELAYOF = punching with delay OFF
Since the PLC normally needs to perform some preliminary tasks with respect to these preparatory
functions, they are programmed before the activating commands.
Group 38
This group contains the commands for switching over to a second punch interface. It can be used, for
example, for a second punching unit or set of hammer shears. A second I/O pair which can be used
for punching functionality is defined via machine data.
SPIF1 = first interface is active
SPIF2 = second interface is active
Note
Only one function at a time can be active within a G code group (similar, for example, to the
various interpolation modes G0, G1, G2, G3, etc. which are also mutually exclusive).
SPOF
Punching and nibbling OFF
The SPOF function terminates all punching and nibbling functions. In this state, the NCK
responds neither to the "Stroke active" signal nor to the PLC signals specific to punching and
nibbling functions.
If SPOF is programmed together with a travel command in one block (and in all further blocks
if punching/nibbling is not activated with SON or PON), the machine approaches the
programmed position without the initiation of a punching operation. SPOF deselects SON, SONS,
PON and PONS and corresponds to the Reset condition.
Programming example:

:
:
N20 G90 X100 SON ; activate nibbling
N25 X50 SPOF ; Deactivate nibbling,
; position without stroke initiation
:
:
Extended Functions
SON
Nibbling ON
SON activates the nibbling function and deselects the other functions in G group35 (e.g. PON).
In contrast to punching, the first stroke is made at the start point of the block with the
activating command, i.e. before the first machine motion.
SON has a modal action, i.e. it remains active until either SPOF or PON is programmed or until
the program end is reached.
The stroke initiation is suppressed in blocks without traversing information relating to the
axes designated as punching or nibbling axes (typically those in the active plane). If a stroke
still needs to be initiated, then one of the punching/nibbling axes must be programmed with a
0 traversing path. If the first block with SON is a block without traversing information of the
type mentioned, then only one stroke takes place in this block since the start and end points
are identical.

:
:
N70 X50 SPOF ; position without punch initiation
N80 X100 SON ; Activate nibbling, initiate a stroke before the
; motion (X=50) and on completion of the programmed
; movement (X=100)
:
:
SONS
Nibbling ON (in position control cycle)
SONS behaves in the same way as SON. The function is activated in the position control cycle,
thus allowing time-optimized stroke initiation and an increase in the punching rate per
minute.
PON
Punching ON
PON activates the punching function and deactivates SON.
PON has a modal action like SON.
In contrast to SON, however, a stroke is not executed until the end of the block or, in the case
of automatic path segmentation, at the end of a path segment. PON has an identical action
to SON in the case of blocks which contain no traversing information.
Extended Functions

:
:
N100 Y30 SPOF ; position without punch initiation
N110 Y100 PON ; Activate punching, punch initiation at the end of the
; positioning operation (Y=100)
:
:
PONS
Punching ON (in position control cycle)
PONS behaves in the same way as PON. For explanation, please refer to SONS.
PDELAYON
Punching with delay ON
PDELAYON is a preparatory function. This means that PDELAYON is generally programmed before
PON. The punch stroke is output with a delay when the programmed end position is reached.
The delay time in seconds is programmed in setting data:
SD42400 $SC_PUNCH_DWELLTIME
If the defined value cannot be divided as an integer into the interpolation clock cycle, then it
is rounded to the next divisible integer value.
The function has a modal action.
PDELAYOF
Punching with delay OFF
PDELAYOF deactivates punching with delay function, i.e. the punching process continues
normally. PDELAYON and PDELAYOF form a G code group.
SPIF2 activates the second punch interface, i.e. the stroke is controlled via the second pair of
high-speed I/Os (see Section "Channelspecific machine data (Page 596)", MD26004 and
MD26006).

:
:
N170 PDELAYON X100 SPOF ; Position without punch initiation, activate
; the delayed punch initiation
:
:
Extended Functions

N180 X800 PON ; activate punching. After reaching the
; end position, the punch stroke is output delayed
:
:
N190 PDELAYOF X700 ; Deactivate punching with delay, normal
; initiation of a punching operation. End of the
programmed
; movement
:
:
:
SPIF1
Activation of first punch interface
SPIF1activates the first punch interface, i.e. the stroke is controlled via the first pair of high-
speed I/Os (see Section "Channelspecific machine data (Page 596)", MD26004 and
MD26006).
The first punch interface is always active after a reset or control system power up. If only one
interface is used, then it need not be programmed.
SPIF2
Activation of second punch interface
SPIF2 activates the second punch interface, i.e. the stroke is controlled via the second pair of
high-speed I/Os (see Section "Channelspecific machine data (Page 596)", MD26004 and
MD26006).

:
:
N170 SPIF1 X100 PON ; At the end of the block, a stroke is initiated at
; the first fast output. The signal "stroke
; active" is monitored at the first input.
:
:
:
:
N180 X800 SPIF2 ; The second stroke is initiated at the
; second fast output. "Stroke active" signal
; is monitored at the second input.
:
:
Extended Functions

:
N190 SPIF1 X700 ; All further strokes are controlled
; with the first interface.
:
9.3.2 Functional expansions
Alternate interface
Machines that alternately use a second punching unit or a comparable medium can be
switched over to a second I/O pair.
The second I/O pair can be defined via the following machine data:
MD26004 $MC_NIBBLE_PUNCH_OUTMASK
MD26006 $MC_NIBBLE_PUNCH_INMASK
The interface is switched by command SPIF1 or SPIF2.
Full punching/nibbling functionality is available on both interfaces.
Example:
Hardware assignment for stroke control
Define the high-speed byte in each case on the CPU as a high-speed punch interface:
MD26000 $MC_PUNCHNIB_ASSIGN_FASTIN = 'H00030001' Byte 1
MD26002 $MC_PUNCHNIB_ASSIGN_FASTOUT = 'H00000001'
Remark:
The first and second bits are inverted.
Screen form for high-speed input and output bits:
First interface output bit

MD26004 $MC_NIBBLE_PUNCH_OUTMASK[0] =1 Bit 1 SPIF1
Second interface output bit
MD26004 $MC_NIBBLE_PUNCH_OUTMASK[1] =2 Bit 2 SPIF2
First interface input bit
MD26006 $MC_NIBBLE_PUNCH_INMASK[0] =1 Bit 1 SPIF1
Second interface input bit
MD26006 $MC_NIBBLE_PUNCH_INMASK[1] =2 Bit 2 SPIF2
Extended Functions
Automatically activated pre-initiation time

Dead times due to the reaction time of the punching unit can be minimized if the stroke can
be initiated before the interpolation window of the axes is reached. The reference time for
this is the interpolation end. The stroke is automatically initiated with G603 and delayed by the
set value in relation to the time that the end of interpolation is reached.
The delay time for stroke initiation can be adjusted in machine data:
MD26018 $MC_NIBBLE_PRE_START_TIME
Example:
With an IPO cycle of 5 ms, a stroke shall be released two cycles after reaching the
interpolation end:
MD26018 $MC_NIBBLE_PRE_START_TIME = 0.01 [s]
A pre-initiation time can also be programmed in setting data:
SD42402 $SC_NIBPUNCH_PRE_START_TIME
This setting takes effective only if MD26018 = 0 has been set.
Monitoring of the input signal

If the "stroke active" signal is fluctuating between strokes due to plunger overshoots, for
example, the message "undefined punching signal" can be also be output when interpolation
is stopped.
The message output is dependent on the setting in machine data:
MD26020 $MC_NIBBLE_SIGNAL_CHECK
MD26020 = 0 No alarm
MD26020 = 1 Alarm
Minimum period between two strokes

A minimum time interval between two consecutive strokes can be programmed in setting
data:
SD42404 $SC_MINTIME_BETWEEN_STROKES
Example:
There must be a minimum delay of at least 1.3 seconds between two stroke initiations
irrespective of physical distance:
SD42404 $SC_MINTIME_BETWEEN_STROKES = 1.3 [s]
If a punching dwell time (PDELAYON) is also programmed, then the two times are applied
additively.
If a pre-initiation time at G603 is programmed, it will be effective only if the end of interpolation
is reached before the time set in SD 42404:
Extended Functions
The programmed time becomes operative immediately. Depending on the size of the block
buffer, strokes that have already been programmed can be executed with this minimum
interval. The following programming measures (example) can be taken to prevent this:
Program code
N...
N100 STOPRE
N110 $SC_ MINTIME_BETWEEN_STROKES = 1.3
The function is not active when SD42404 = 0.
Travel-dependent acceleration
An acceleration characteristic can be defined with PUNCHACC (Smin, Amin, Smax, Amax). This
command can be used to define different acceleration rates depending on the distance
between holes.
Example 1:
$>@

381&+$&&

6>PP@
The characteristic defines the following acceleration rates:
Distance Acceleration
between holes
< 2 mm The axis accelerates at a rate corresponding to 50 % of maximum acceleration.
2 - 10 mm Acceleration is increased to 100 %, proportional to the spacing.
> 10 mm The axis accelerates at the maximum rate (100%).
Extended Functions
Example 2:
$>@

381&+$&&

6>PP@
The characteristic defines the following acceleration rates:
Distance Acceleration
between holes
< 3 mm The axis accelerates at a rate corresponding to 75 % of maximum acceleration.
3 - 8 mm Acceleration is reduced to 25 %, proportional to the spacing.
> 10 mm The axis accelerates at the maximum rate (25 %).
If a reduced acceleration rate has already been programmed via ACC, then the acceleration
limits defined with PUNCHACC refer to the reduced acceleration rate.
The function is deselected with:
Smin = Smax = 0
The acceleration rate programmed beforehand with ACC remains operative.
Extended Functions
Block search
In the case of a search for a block containing a nibbling function, it is possible to program
whether the punch stroke is executed at the block beginning or suppressed.
The setting is programmed in machine data:
MD11450 $MN_SEARCH_RUN_MODE
Bit Value Meaning

5 0 Punch stroke at beginning of block is suppressed.
1 Punch stroke at beginning of block is executed.
References:
Response (K1), Section:
9.3.3 Compatibility with earlier systems
Use of M functions
As in earlier versions, macro technology allows special M functions to be used instead of
language commands (compatibility).
The M functions and equivalent language commands as used in earlier systems are as
follows:
M20, M23 SPOF

M22
SON
M25
PON
M26
PDELAYON
Note
M functions can be configured in machine data.
When M functions are assigned to language commands, it must be noted that M functions
are organized in auxiliary function groups.
Extended Functions
Examples
DEFINE M20 AS SPOF

Punching/nibbling OFF
or
DEFINE M20 AS SPOF M=20
Punching with auxiliary function output
DEFINE M20 AS SPOF PDELAYOF

Punching/nibbling OFF and punching with delay OFF
DEFINE M22 AS SON

Nibbling ON
or
DEFINE M22 AS SON M=22
Nibbling ON with auxiliary function output
DEFINE M25 AS PON

Punching ON
or
DEFINE M25 AS PON M=25
Punching ON with auxiliary function output
DEFINE M26 AS PDELAYON

Punching with delay ON
or
DEFINE M26 AS PDELAYON M=26
Punching and auxiliary function output

:
:
N100 X100 M20 ; position without punch initiation
N110 X120 M22 ; Activate nibbling, before and after motion
; stroke initiation
:
N120 X150 Y150 M25 ; Activate punching, initiate stroke at end
; of the motion
:
:
Extended Functions
9.4 Automatic path segmentation
Function
One of the following two methods can be applied to automatically segment a programmed
traversing path:
Path segmentation with maximum path segment programmed via language command SPP
Path segmentation with a number of segments programmed via language command SPN
Both functions generate sub-blocks independently.
In earlier systems
SPP<number> corresponds to E<number>
SPN<number> corresponds to H<number>
Since addresses E and H now represent auxiliary functions, language commands SPP and SPN
are used to avoid conflicts. The new procedure is therefore not compatible with those
implemented in earlier systems. Both language commands (SPP and SPN) can be configured.
Note
The values programmed with SPP are either mm or inch settings depending on the initial
setting (analogous to axes).
The automatic path segmentation function ensures that the path is divided into equidistant
sections with linear and circle interpolation.
When the program is interrupted and automatic path segmentation is active (SPP/SPN), the
contour can be reentered only at the beginning of the segmented block. The first punch
stroke is executed at the end of this sub-block.
SPP and SPN can be activated only if geometry axes are configured.
SPP
The automatic path segmentation function SPP divides the programmed traversing path into
sections of equal size according to the segment specification.
The following conditions apply:
Path segmentation is active only when SON or PON is active.
(Exception: MD26014 $MC_PUNCH_PATH_SPLITTING = 1)
SPPis modally active, i.e. the programmed segment remains valid until it is programmed
again, but it can be suppressed on a block-by-block (non-modal) basis by means of SPN.
Extended Functions
The path segments are rounded off by the control system if required so that a total
programmed distance can be divided into an integral number of path sections.
The path segment unit is either mm/stroke or inch/stroke (depending on axis settings).
If the programmed SPP value is greater than the traversing distance, then the axis is
positioned on the programmed end position without path segmentation.
SPP = 0, reset or program end delete the programmed SPP value. The SPP value is not
deleted when punching/nibbling is deactivated.
SPN
The automatic path segmentation function SPN divides the traversing path into the
programmed number of path segments.
The following conditions apply:
Path segmentation is active only when SON or PON is active.
(Exception: MD26014 $MC_PUNCH_PATH_SPLITTING = 1)
SPN has a non-modal action.
Any previously programmed SPP value is suppressed for the block containing SPN, but is
re-activated again in the following blocks.
The path segmentation function is operative with linear and circular interpolation.
The interpolation mode remains unchanged, i.e. circles are traversed when circular
interpolation is selected.
If a block contains both SPN (number of strokes) and SPP (stroke path), then the number of
blocks is activated in the current block while the stroke path is activated in all blocks that
follow.
Path segmentation is active only in conjunction with punching or nibbling functions.
(Exception: MD26014 $MC_PUNCH_PATH_SPLITTING = 1).
Any programmed auxiliary functions are output before, during the first or after the last
sub-block.
In the case of blocks without traversing information, the rules which govern the
programming of SON and PON also apply to SPP and SPN. In other words, a stroke is initiated
only if an axis motion has been programmed.
Extended Functions
9.4.2 Operating characteristics with path axes
MD26010
All axes defined and programmed via machine data:
MD26010 $MC_PUNCHNIB_AXIS_MASK
are traversed along path sections of identical size with SPP and SPN until the programmed
end point is reached. This also applies to rotatable tool axes if programmed. The response
can be adjusted for single axes.
Example of SPP

N1 G01 X0 Y0 SPOF ; Position without punch initiation
N2 X75 SPP=25 SON ; Nibble with feed value 25 mm; initiate punch
; before the first movement and after each
; path section,
:
:
N3 Y10 ; Position with reduced SPP value, because
: ; traversing distance < SPP value, and initiate punch
; after the movement.
:
:
N4 X0 ; Reposition with punch initiation
; after each path section.
:
633

633
Extended Functions
If the programmed path segmentation is not an integral multiple of the total path, then the
feed path is reduced.
<
<
633
633
;
;
X2/Y2: Programmed traversing distance

SPP: Programmed SPP value
SPP': Automatically rounded-off offset distance
Figure 9-4 Path segmentation
Example of SPN
The number of path segments per block is programmed via SPN.
A value programmed via SPN takes effect on a non-modal basis for both punching and
nibbling applications. The only difference between the two modes is with respect to the first
stroke. This is normally executed at the beginning of the first segment with nibbling
operations and at its end with punching operations. This means that when n segments are
programmed, n strokes are executed with punching operations but n+1 with nibbling.
Furthermore, where no travel information is available, only a single stroke is executed, even
if several are programmed. Should it be necessary to generate several strokes at one
position, then the corresponding number of blocks without traversing information must be
programmed.
Extended Functions

N1 G01 X0 Y0 SPOF ; position without punch initiation
N2 X75 SPN=3 SON ; Activate nibbling. The total path is
; divided into three segments. Before the first
; movement and at the end of each segment, a
; stroke is triggered.
:
:
:
:
N3 Y10 SPOF ; Position without punch initiation
N4 X0 SPN=2 PON ; activate punching. The total path is divided into 2
; path segments. Because punching has been activated,
; the first stroke is initiated at the end of the first
path segment.
;
:
:
:
:
631

631
Extended Functions
Example

;

<

Figure 9-5 Workpiece
Extract from program

N100 G90 X130 Y75 F60 SPOF ; Positioning to starting point (1) of the
; vertical nibbling path sections
N110 G91 Y125 SPP=4 SON ; End point coordinates (incremental)
; Path segment: 4 mm, activate nibbling
N120 G90 Y250 SPOF ; Absolute dimensioning, position at
; the start point (2) of the horizontal
; nibbling path section
N130 X365 SPN=4 SON ; End point coordinates, four path sections,
; activate nibbling
N140 X525 SPOF ; Positioning to starting point (3) of the
; oblique nibbling path
N150 X210 Y75 SPP=3 SON ; End point coordinates path segment: 3 mm,
; activate nibbling
N160 X525 SPOF ; Positioning to starting point (4) of the
; nibbling path on pitch circle path
Extended Functions

N170 G02 G91 X-62.5 Y62.5 I0 J62.5 SON ; Incremental circular interpolation with
; interpolation parameters, nibbling
; activating
N180 G00 G90 Y300 SPOF ; Positioning
9.4.3 Response in connection with single axes
MD26016
The path of single axes programmed in addition to path axes is distributed evenly among the
generated intermediate blocks as standard.
In the following example, the additional rotary axis C is defined as a synchronous axis.
If this axis is programmed additionally as a "Punch-nibble axis":
MD26010 $MC_PUNCHNIB_AXIS_MASK = 1,
, then the behavior of the synchronous axis can be varied as a function of machine data:
MD26016 $MC_PUNCH_PARTITION_TYPE
.
Program code
N10 G90 G1 PON X10 Y10 C0 F10000
N20 SPP=5 X25 C45
N30 G3 SPN=3 X35 Y20 I0 J10 C90
Extended Functions
MD26016 $MC_PUNCH_PARTITION_TYPE=0 (default setting)

With this setting, the axes behave as standard, i.e. the programmed special axis motions are
distributed among the generated intermediate blocks of the active path segmentation
function in all interpolation modes.
In block N20, the C axis is rotated through 15 in each of the three intermediate blocks. The
axis response is the same in block N30, in the case of circular interpolation (three sub-blocks,
each with 15 axis rotation).

r

r
r

1 1
& r r r r

[
Extended Functions
MD26016 $MC_PUNCH_PARTITION_TYPE=1
In contrast to the behavior described above, here the synchronous axis travels the entire
programmed rotation path in the first sub-block of the selected path segmentation function.
Applied to the example, the C axis already reaches the programmed end position C=45 when
it reaches X position X=15. It behaves in the same way in the circular interpolation block
below.

r

r
r
1 1 1
& r r r r

[
Extended Functions
MD26016 $MC_PUNCH_PARTITION_TYPE=2
MD26016=2 is set in cases where the axis must behave as described above in linear
interpolation mode, but according to the default setting in circular interpolation mode (see 1st
case).
The axis behavior for the example is then as follows: In block N20, the C axis is rotated to
C=45 in the first sub-block. The following circular interpolation block rotates the C axis
through 15 in every sub-block.

r

r
r

1 1 1
& r r r r

[
The axis response illustrated in the diagram above can be particularly useful when applied to
the axis of a rotatable tool in cases where it is used to place the tool in a defined direction
(e.g. tangential) in relation to the contour, but where the tangential control function must not
be applied. However, it is not a substitute for the tangential control function since the start
and end positions of the rotary axis must always be programmed.
Note
Additional offset motions of special axes (in this case, rotary axis C) are implemented via a
zero offset.
Extended Functions
If the C axis is not defined as a "Punch-nibble axis", then the C axis motion path is not
segmented in block N30 in the above example nor is a stroke initiated at the block end.
If the functionality described above is to be implemented in a variant not specific to
nibbling applications, but with alignment of the special axis, then stroke initiation can be
suppressed by the following PLC interface signal:
DB 21, 22 DBX3.2 (stroke suppression)
(Application: e.g. alignment of electron beam during welding)
A similar response can be programmed with the following machine data setting:
MD26014 $MC_PUNCH_PATH_SPLITTING=1
In this case, the path is segmented irrespective of punching or nibbling functions.
Extended Functions
9.5 Rotatable tool
9.5 Rotatable tool
Function overview
The following two functions are provided for nibbling/punching machines with rotatable
punch and lower die:
Coupled motion
for synchronous rotation of punch and die
Tangential control
for normal alignment of rotary axes for punches in relation to workpiece
7RROURWDU\D[LV
6WDPS
'LH
Figure 9-6 Illustration of a rotatable tool axis
Extended Functions
9.5 Rotatable tool
9.5.2 Coupled motion of punch and die
Function
Using the standard function "Coupled motion", it is possible to assign the axis of the die as a
coupled motion axis to the rotary axis of the punch.
Activation
The "Coupled motion" function is activated or deactivated with language commands TRAILON
and TRAILOF respectively.
References:
Function Manual, Special Functions; Coupled Motion and ESR (M3)
Example
Example of a typical nibbling machine with rotatable punches where C is the punch axis and
C1 the die axis:

:
:
TRAILON (C1, C, 1) ; Enabling the coupled-motion grouping
G01 X100 Y100 C0 PON ; Initiate stroke with C axis /
; C1 axis position C=0=C1
X150 C45 ; Initiate stroke with C axis /
; C1 axis position C=45=C1
:
:
M30
Basic position
No coupled-motion groupings are active after power up. Once the two tool axes have
approached the reference point, the coupled-motion grouping is not generally separated
again.
This can be achieved by:
Program single activation of the coupled-motion grouping (see example above)
Program MD setting:
MD20110 $MC_RESET_MODE_MASK, bit 8=1
In this way, the coupled-motion grouping remains active after RESET/part program start or
end.
Extended Functions
9.5 Rotatable tool
9.5.3 Tangential control
Function
The rotary tool axes on punching/nibbling machines are aligned tangentially to the
programmed path of the master axes by means of the "Tangential control" function.
Activation
The "Tangential control" function is activated and deactivated with language commands
TANGON and TANGOF respectively.
References:
Programming Manual, Production Planning
Mode of operation
The tangential axis is coupled to the interpolation of the master axes. It is therefore not
possible to position the axis at the appropriate punching position tangentially to the path
independently of velocity. This may lead to a reduction in machining velocity if the dynamics
of the rotary axis are unfavorable in relation to those of the master axes. Additional offset
angles can be programmed directly via language command TANGON.
Note
If the tool (punch and die) is positioned by two separate drives, then the functions
"Tangential control" and "Coupled motion" can be used.
Notice: The "Tangential control" function must be activated first followed by "Coupled
motion".
The tangential control function automatically aligns the punch vertically to the direction vector
of the programmed path. The tangential tool is positioned before the first punching operation
is executed along the programmed path. The tangential angle is always referred to the
positive X axis. A programmed additional angle is added to the calculated angle.
The tangential control function can be used in the linear and circular interpolation modes.
Extended Functions
9.5 Rotatable tool
Example: Linear interpolation

The punching/nibbling machine has a rotatable punch and die with separate drives.

:
:
N2 TANG (C, X, Y, 1, "B") ; Definition of leading and following axes,
; C is the slave axis for X and Y in the
; basic coordinate system
N5 G0 X10 Y5 ; Start position
N8 TRAILON (C1, C, 1) ; Activate coupled motion of rotatable
; tool axes C/C1
N10 Y10 C225 PON F60 ; C/C1 axis rotates to 225 stroke
N15 X20 Y20 C45 ; C/C1 axis rotates to 45 stroke
N20 X50 Y20 C90 SPOF ; C/C1 axis rotates to 90, no
; stroke initiation
N25 X80 Y20 SPP=10 SON ; Path segmentation: four strokes are performed
; with tool rotated to 90
N30 X60 Y40 SPOF ; Positioning
N32 TANGON (C, 180) ; Activate tangential control,
; offset angle of rotatable tool axes 180
N35 X30 Y70 SPN=3 PON ; Path segmentation, three strokes for active
; tangential control and an
; offset angle of 180
N40 G91 C45 X-10 Y-10 ; C/C1 rotates to 225 (180 + 45 INC),
; Tangential control deactivated because no
; path segmentation stroke
N42 TANGON (C, 0) ; Tangential control without offset
N45 G90 Y30 SPN=3 SON ; Path segmentation, three strokes for active
; Tangential control without offset angle
N50 SPOF TANGOF ; Deactivate stroke initiation +
; Tangential control
N55 TRAILOF (C1, C) ; Activate coupled motion of rotatable
; tool axes C/C1
N60 M2
Extended Functions
9.5 Rotatable tool
;
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1
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1 1
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3XQFKLQJ

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1

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1
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Figure 9-7 Illustration of programming example in XY plane
Example: Circular interpolation

In circular interpolation mode, particularly when path segmentation is active, the tool axes
rotate along a path tangentially aligned to the programmed path axes in each sub-block.

:
:
N2 TANG (C, X, Y, 1, "B") ; Definition of leading and following
axes,
; C is the slave axis for X and Y in the
; basic coordinate system
N5 G0 F60 X10 Y10 ; Start position
N8 TRAILON (C1, C, 1) ; Activate coupled motion of the
; rotatable tool axes C/C1
; for lower and upper tool
N9 TANGON (C, -90) ; Activate tangential control
; with offset 270
N10 G02 X30 Y30 I20 J0 SPN=2 PON ; Circular interpolation with path
segmentation,
; 2 strokes are executed with 270
Extended Functions
9.5 Rotatable tool

; Offset angle and tangential
; alignment along the circular path
N15 G0 X70 Y10 SPOF ; Positioning
N17 TANGON (C, 90) ; Activate tangential control
; with offset 90
N20 G03 X35,86 Y24,14 CR=20 SPP=16 SON ; Circular interpolation, path
segmentation, 4
; strokes are performed with 90
; offset angle and tangential
; alignment along the circular path
N25 G0 X74.14 Y35.86 C0 PON ; Rotation of the tool axes to
; 0, stroke
N27 TANGON (C, 0) ; Activate tangential control
; with offset 0
N30 G03 X40 Y50 I-14,14 J14,14 SPN=5 SON ; Circular interpolation, path
segmentation,
; 5 strokes with 0 offset angle
; and tangential alignment on
; the circular path
N35 G0 X30 Y65 C90 SPOF ; Position without active
; tangential control
N40 G91 X-10 Y-25 C180 ; Positioning, C axis rotates to 270
N43 TANGOF ; Deactivate tangential control
N45 G90 G02 Y60 I0 J10 SPP=2 PON ; Circular interpolation, path
segmentation,
; Two strokes without tangential control
; with C=270
N50 SPOF ; Punching OFF
N55 TRAILOF (C1, C) ; Deactivate coupled motion of the
; rotatable tool axes C/C1
N60 M2
Extended Functions
9.6 Protection zones
;
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1 1 1

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Figure 9-8 Illustration of programming example in XY plane
9.6 Protection zones
Clamping protection zone

The "clamping protection zone" function is contained as a subset in the "Protection zones"
function. Its purpose is to simply monitor whether clamps and tool could represent a mutual
risk.
Note
No by-pass strategies are implemented for cases where the clamp protection is violated.
References:
9.7 Supplementary conditions
Availability of function "Punching and nibbling"

The function is an option ("Punching and nibbling functions"), which must be assigned to the
hardware through the license management.
Extended Functions
9.8 Examples
9.8 Examples
9.8.1 Examples of defined start of nibbling operation
Example 1
Example of defined start of nibbling operation

:
:
N10 G0 X20 Y120 SPP= 20 ; Position 1 is approached
N20 X120 SON ; Defined start of nibbling, first stroke at
; "1", last stroke at "2"
N30 Y20 ; Defined start of nibbling, first stroke at
N40 X20 ; Defined start of nibbling, first stroke at
N50 SPOF
N60 M2
;

<
Extended Functions
9.8 Examples
Example 2
This example utilizes the "Tangential control" function. Z has been selected as the name of
the tangential axis.

:
:
N5 TANG (Z, X, Y, 1, "B") ; Define tangential axis
N8 TANGON (Z, 0) ; Select tangential control
N10 G0 X20 Y120 ; Position 1 is approached
N20 X120 SPP=20 SON ; Defined start of nibbling,
; tangential control selected,
; first stroke at "1", last stroke at "2"
N30 SPOF TANGOF ; Deselect nibbling mode and deselect
N38 TANGON (Z, 90) ; Select tangential control
N40 Y20 SON ; Defined start of nibbling,
; tangential control selected,
; first stroke at "2" rotated 90 degrees to
; block N20, last stroke at "3"
N50 SPOF TANGOF ; Deselect nibbling mode and deselect
N60 M2
;

<
Extended Functions
9.8 Examples
Examples 3 and 4 for defined start of nibbling
Example 3: Programming of SPP

:
:
N5 G0 X10 Y10 ; Positioning
N10 X90 SPP=20 SON ; Defined start of nibbling,
; 5 punches initiated
N20 X10 Y30 SPP=0 ; One punch is initiated at the end of the path
N30 X90 SPP=20 ; 4 punches initiated at intervals of 20 mm
N40 SPOF
N50 M2
Example 4 Programming of SPN

:
:
N10 X90 SPN=4 SON ; Defined start of nibbling, 5
N20 X10 Y30 PON ; One punch is initiated at the end of the path
N30 X90 SPN=4 ; 4 punches initiated
N40 SPOF
N50 M2
;

1 1 1 <
Figure 9-9 Examples 3 and 4 for defined start of nibbling
Extended Functions
9.8 Examples
Examples 5 and 6 without defined start of nibbling
Example 5 Programming of SPP

:
:
N10 X90 SPP=20 PON ; No defined start of nibbling,
N15 Y10 ; One punch is initiated at the end of the path
N20 X10 SPP=20 ; 4 punches initiated at intervals of 20 mm
N25 SPOF
N30 M2
Example 6 Programming of SPN

:
:
N10 X90 SPN=4 PON ; No defined start of nibbling,
N15 Y10 ; One punch is initiated at the end of the path
N20 X10 SPN=4 ; 4 punches initiated
N25 SPOF
N30 M2
Extended Functions
9.8 Examples
Example 7 Application example of SPP programming

;

<

Figure 9-10 Workpiece
Extract from program:

N100 G90 X75 Y75 F60 PON ; Positioning to starting point (1) of the
; vertical line of holes, punch single hole
N110 G91 Y125 SPP=25 PON ; End point coordinates (incremental),
; path segment: 25 mm, activate punching
N120 G90 X150 SPOF ; Absolute dimensioning, position at
; the start point (2) of the horizontal line of
holes
N130 X375 SPP=45 PON ; End point coordinates, path segment: 45 mm
N140 X275 Y160 SPOF ; Positioning to starting point (3) of the
; oblique line of holes
N150 X150 Y75 SPP=40 PON ; End point coordinates, programmed
; path segment: 40 mm, calculated
; path segment: 37.39 mm
N160 G00 Y300 SPOF ; Positioning
Extended Functions
9.9 Data lists
9.9 Data lists
9.9.1 Machine data

11450 SEARCH_RUN_MODE Block search parameter settings

20150 GCODE_RESET_VALUES[n] Reset G groups
26000 PUNCHNIB_ASSIGN_FASTIN Hardware assignment for input-byte with stroke
control
26002 PUNCHNIB_ASSIGN_FASTOUT Hardware assignment for output-byte with stroke
control
26004 NIBBLE_PUNCH_OUTMASK[n]) Mask for quick output bits
26006 NIBBLE_PUNCH_INMASK[n] Mask for quick input bits
26008 NIBBLE_PUNCH_CODE[n] Determination of the M functions
26010 PUNCHNIB_AXIS_MASK Definition of punching and nibbling axes
26012 PUNCHNIB_ACTIVATION Activation of punching and nibbling functions
26014 PUNCH_PATH_SPLITTING Activation of automatic path segmentation
26016 PUNCH_PARTITION_TYPE Behavior of single axes with active automatic path
segmentation
26018 NIBBLE_PRE_START_TIME Automatically activated pre-initiation time
26020 NIBBLE_SIGNAL_CHECK Monitoring of the input signal
9.9.2 Setting data

42400 PUNCH_DWELL_TIME Dwell time
42402 NIBPUNCH_PRE_START_TIME Pre-start time
42404 MINTIME_BETWEEN_STROKES Minimum time interval between two consecutive
strokes
Extended Functions
9.9 Data lists
9.9.3 Signals

No stroke enable DB21, ... .DBX3.0 -
Manual stroke initiation DB21, ... .DBX3.1 -
Stroke suppression DB21, ... .DBX3.2 -
Stroke inoperative DB21, ... .DBX3.3 -
Delayed stroke DB21, ... .DBX3.4 -
Manual stroke initiation DB21, ... .DBX3.5 -

Stroke initiation active DB21, ... .DBX38.0 -
Acknowledgement of manual stroke initiation DB21, ... .DBX38.1 -
9.9.4 Language commands
G group Language Meaning

command
35 SPOF Stroke / Punch OFF Punching and nibbling OFF
35 SON Stroke ON Nibbling ON
35 SONS Stroke ON Nibbling ON (position controller)
35 PON Punch ON Punching ON
35 PONS Punch ON Punching ON (position controller)
36 PDELAYON Punch with Delay ON Punching with delay ON
36 PDELAYOF Punch with Delay OFF Punching with delay OFF
Path segmentation
SPP Path per stroke, modal action
SPN Number of strokes per block, non-modal action
Extended Functions
9.9 Data lists
Extended Functions
P2: Positioning axes 10
10.1 Product brief
Axes for auxiliary movements

In addition to axes for machining a workpiece, modern machine tools can also be equipped
with axes for auxiliary movements, e.g.:
Axis for tool magazine
Axis for tool turret
Axis for workpiece transport
Axis for pallet transport
Axis for loader (also multi-axis)
Axis for tool changer
Axis for sleeve assembly / end support
The axes for the workpiece machining are called path axes. Within the channel they are
guided by the interpolator such that they start simultaneously, accelerate, reach the end
point and stop together.
Axes for auxiliary movements are traversed independently of the path axes at a separate,
axis-specific feedrate. In the past, many of these axes were moved hydraulically and started
by an auxiliary function in the part program. With the closed-loop axis control implemented in
the NC, the axis can be addressed by name in the part program and its actual position
displayed on the screen.
Extended Functions
P2: Positioning axes
10.1 Product brief
Note
"Positioning axis/Auxiliary spindle" option
Axes for auxiliary movements must not be interpolating ("full-value") NC axes. Auxiliary
movements may also be carried out using special axes, which can be obtained using the
"Positioning axis/Auxiliary spindle" option.
Functional restrictions
Optional positioning axes/auxiliary spindles have fewer functions. The following functions are
not possible:
Using the axis as a path axis, geometry axis, or special path axis
Incorporating the axis into the geometry axis grouping (GEOAX)
Rigid thread cutting and tapping
Commissioning
As standard, axes are defined as interpolating axes:
MD30460 $MA_BASE_FUNCTION_MASK bit 8 = 0
If an axis is to be operated as a positioning axis/auxiliary spindle with reduced functionality,
the value for bit 8 must be set to "1":
MD30460 $MA_BASE_FUNCTION_MASK bit 8 = 1
Function
The "positioning axes" function makes it easier to integrate axes for auxiliary movement into
the control system:
during programming:
The axes are programmed together with the axes for workpiece machining in the same
part program, without having to sacrifice valuable machining time.
There are special (POS, POSA) traversing instructions.
during program testing/start-up:
Program testing and start-up are performed simultaneously for all axes.
during operation:
Operation and monitoring of the machining process commence simultaneously for all
axes.
during PLC configuring/commissioning:
No allowance has to be made on PLC or external computers (PCs) for synchronization
between axes for machining and axes for auxiliary movements.
during system configuring:
A second channel is not required.
Extended Functions
10.2 Own channel, positioning axis or concurrent positioning axis
Motions and interpolations

Each channel has one path interpolator and at least one axis interpolator with the following
interpolation functions:
for path interpolator:
Linear interpolation (G1), circular interpolation (G2 / G3), spline interpolation, etc.
for axis interpolator:
If a positioning axis is programmed, an axis interpolator starts in the control (with linear
interpolation G1).
End-of-motion criterion:
The programmed end position of a positioning axis has been reached when the end-of-
motion criterion FINEA, COARSA or IPOENDA is fulfilled.
Path axes with rapid traverse movement:
Path axes can be traversed in linear or non-linear interpolation mode with rapid traverse
movement (G0).
Autonomous singleaxis operations:
Single PLC axes, command axes started via static synchronized actions or asynchronous
reciprocating axes can be interpolated independently of the NCK.
An axis/spindle interpolated by the main run then reacts independently of the NC
program. The channel response triggered by the program run is decoupled to transfer the
control of a certain axis / spindle to the PLC.
Control by PLC:
All channel-specific signals normally act to the same extent on path and positioning axes.
Positioning axes can be controlled via additional, axis-specific signals.
PLC axes are traversed by the PLC via special function blocks in the basic program; their
movements can be asynchronous to all other axes. The travel motions are executed
separate from the path and synchronized actions.

When axes are provided for auxiliary movements on a machine tool, the required properties
will decide whether the axis is to be:
programmed in an internal part program (see Section "Own channel - only 840D sl
(Page 602)").
programmed in the same part program as the machining operation (see Section
"Positioning axis (Page 602)").
started exclusively by the PLC during machining (see Section "Concurrent positioning
axis (Page 605)").
Extended Functions
10.2.1 Own channel - only 840D sl

A channel represents a self-contained NC which, with the aid of a part program, can be used
to control the movement of axes, spindles and machine functions independently of other
channels.
Non-dependence between channels

Independence between channels is assured by means of the following provisions:
An active part program per channel
Channelspecific interface signals such as
DB21, ... DBX7.1 (NC start)
DB21, ... DBX7.3 (NC stop)
One feedrate override per channel
One rapid traverse override per channel
Channelspecific evaluation and display of alarms
Channelspecific display, e.g. for
Actual axis positions
Active G functions
Active auxiliary functions
Current program block
Channel-specific testing and channel-specific control of programs:
Single block
Dry run (DRY RUN)
Block search
Program test
References
For more information on the channel functionality, please refer to:
function manual, Basic Functions; BAG, Channel, Program Operation, Reset Response (K1)
10.2.2 Positioning axis

Positioning axes are programmed together with path axes, i.e. with the axes that are
responsible for workpiece machining.
Commands for positioning axes and path axes can be included in the same NC block.
Although they are programmed in the same NC block, the path and positioning axes are not
interpolated together and do not reach their end point simultaneously (no direct time
relationship, see also Section "Motion behavior and interpolation functions (Page 606)").
Extended Functions
Positioning axis types and block change

The block change time depends on the programmed positioning axis type (refer also to
Section "Block change (Page 621)"):
Type Description
1 The block change occurs when all path and positioning axes have reached their
programmed end point.
2 The block change occurs when all path axes have reached their programmed end point.
With positioning axis type 2, it is possible to approach the programmed end point across
several block limits.
3 It is possible to set the block change within the braking ramp of the single axis interpolation if
the criteria for the motion end and the block change are fulfilled for the path interpolation.
Motion synchronization
Positioning axes permit movements to be activated from the same machining program and
such movements to be synchronized at block limits (type 1) or at explicit points by means of
a WAITP command (type 2).
Motion end criterion for block change in the brake ramp

For single-axis interpolation, it is also possible to set another end-of-motion criterion for the
block change in the braking ramp.
Traverse path axes in G0 as positioning axis

Each path axis can be traversed as positioning axis in rapid traverse movement (G0). Thus all
axes travel to their end point independently.
In this way, two sequentially programmed X and Z axes are treated like positioning axes in
conjunction with G0. The block change to axis Z can be initiated by axis X as a function of the
braking ramp time setting (100-0%). Axis Z starts to move while axis X is still in motion. Both
axes approach their end point independently of one another.
Axis types
Positioning axes can be linear axes and rotary axes.
Positioning axes can also be configured as indexing axes.
Independence of positioning axes and path axes

The mutual independence of positioning and path axes is ensured by the following
measures:
No shared interpolation
Each positioning axis has a dedicated axis interpolator
Dedicated feed override for each positioning axis
Dedicated programmable feedrate
Dedicated "axis-specific delete distance-to-go" interface signal
Extended Functions
Dependencies
Positioning axes are dependent in the following respects:
A shared part program
Starting of positioning axes only at block boundaries in the part program
With rapid traverse movement G0 path axes traverse as positioning axes in one of two
different modes
No rapid traverse override
The following interface signals act on the entire channel and therefore on positioning
axes:
DB21, ... DBX7.1 (NC start)
DB21, ... DBX7.3 (NC stop)
DB21, ... DBX6.1 (read-in disable)
Alarms specific to program and channel also deactivate positioning axes.
Program control (dry run feed, program test, DRF, ... etc.) also act on positioning axes
Block search and single block also act on positioning axes.
The last block with a programmed end-of-motion criterion that was processed in the
search run serves as a container for setting all axes.
Group 1 (modal movement commands) of the G functions G0, G1, G2, ...) does not apply to
positioning axes.
References:
Programming Manual Fundamentals.
Applications
The following are typical applications for positioning axes:
Single-axis loaders
Multi-axis loaders without interpolation (PTP point-to-point traversing)
Workpiece feed and transport
Other applications are also possible:
With G0 workpiece delivery and workpiece transport can travel to their end points
independently of one another.
On machines with several machining processes in sequence: Significant reduction in
individual machining steps due to block change in the braking ramp of the single-axis
interpolation.
Note
Positioning axes are not suitable for multi-axis loaders that require interpolation between
the axes (path interpolator).
Extended Functions
10.2.3 Concurrent positioning axis

Concurrent positioning axes are positioning axes with the following properties:
Activation from the PLC need not take place at block limits, but can be implemented at
any time in any operating mode (even when a part program is already being processed in
the channel).
Program command WAITP is required to move a concurrent positioning axis from the part
program immediately after power ON.
The part program continues to run uninhibited, even if the concurrent positioning axis has
not reached the position defined by the PLC.
An automatic axis change is possible, depending on the setting in the machine data
MD30552 $MA_AUTO_GET_TYPE.
With programming commands:
GET(<axis>) or WAITP(<axis>) becomes a concurrent positioning axis of the channel
axis again.
"RELEASE (axis)" or WAITP(<axis>) is a channel axis that becomes a concurrent axis
under PLC control.
Activation from PLC

For SINUMERIK 840D sl, the concurrent positioning axis is activated via FC 18 from the
PLC.
Feedrate
For feedrate = 0, the feedrate is determined from the following machine data:
Absolute dimensions (G90), incremental dimensions (G91)
Absolute dimensions along shortest path for rotary axes (<rotary axis
name>=DC(<value>))
The following functions are defined:

Linear interpolation (G1)
Feedrate in mm/min or degrees/min (G94)
Exact stop (G9)
Settable zero offsets currently selected are valid
Applications
Typical applications for concurrent positioning axes include:
Tool magazines with manual loading and unloading during machining
Tool magazines with tool preparation during machining
Extended Functions
10.3 Motion behavior and interpolation functions
10.3.1 Path interpolator and axis interpolator
Path interpolator
Every channel has a path interpolator for a wide range of interpolation modes such as linear
interpolation (G1), circular interpolation (G2/G3), spline interpolation etc.
Axis interpolator
Each channel has axis interpolators in addition to path interpolators. The maximum number
corresponds to the maximum number of existing channel axes.
If a positioning axis is programmed, an axis interpolator starts in the control with straight line
interpolation G1. This axis interpolator runs independently of the path interpolator until the
programmed end position of the positioning axis has been reached.
There is no time relationship between the path interpolator and the axis interpolator, nor
between the axis interpolators.
Path control mode (G64) is not possible with positioning axes.
The programmed end position of a positioning axis has been reached when the end-of-
motion criterion FINEA, COARSA or IPOENDA is fulfilled.
10.3.2 Interpolation response of path axis in G0

Path axes can be traversed in linear or non-linear interpolation mode in rapid traverse
movement (G0).
Linear interpolation
Properties:
The path axes are interpolated together.
The tool movement programmed with G0 is executed at the highest possible speed (rapid
traverse).
The rapid traverse velocity is defined separately for each axis in the following machine
data:
MD32000 $MA_MAX_AX_VELO
If the rapid traverse movement is executed simultaneously on several axes, the rapid
traverse speed is determined by the axis which requires the most time for its section of
the path.
Extended Functions
Linear interpolation is always performed in the following cases:

For a G-code combination with G0 that does not allow positioning axis motion, e.g.:
G40, G41, G42, G96, G961 and MD20750 $MC_ALLOW_G0_IN_G96 == FALSE
With a combination of G0 with G64
When a compressor or transformation is active
In point-to-point (PTP) travel mode
When a contour handwheel is selected (FD=0)
In case of an active frame with rotation of geometry axes
If nibbling is active for geometry axes
Non-linear interpolation
Properties:
Each path axis interpolates as a single axis (positioning axis) independently of the other
axes at the rapid traverse velocity defined in the following machine data:
MD32000 $MA_MAX_AX_VELO
The channel-specific delete distance-to-go command via the PLC and synchronized
actions is applied to all positioning axes that were programmed as path axes.
In non-linear interpolation, with reference to the axial jerk:
The setting of the concerned positioning axes BRISKA, SOFTA, DRIVEA
or
The setting in the machine data:
MD32420 $MA_JOG_AND_POS_JERK_ENABLE
and
MD32430 $MA_JOG_AND_POS_MAX_JERK
The existing system variables which refer to the distance-to-go ($AC_PATH, $AC_PLTBB
and $AC_PLTEB) are supported.
CAUTION
Risk of collision
As traversal of another contour is possible with non-linear interpolation, synchronized
actions that refer to coordinates of the original path may not be active.
Extended Functions
Selection of interpolation type

The interpolation type that should be effective for G0 is adjusted with the following machine
data:
MD20730 $MC_G0_LINEAR_MODE (interpolation response in G0)
Value Meaning
0 In the rapid traversing mode (G0) the non-linear interpolation is active.
Path axes are traversed as positioning axes.
1 In the rapid traversing mode (G0) the linear interpolation is active.
The path axes are interpolated together.
The desired interpolation response in G0 can also be programmed via the two following part
program commands, independently of the default:
RTLIOF
Deactivating the linear interpolation.
In the rapid traversing mode (G0), the non-linear interpolation is active.
RTLION
Activating the linear interpolation.
In the rapid traversing mode (G0), the linear interpolation is active.
The currently set interpolation response of the path axes with G0 can be queried with system
variable $AA_G0MODE.
Note
In both interpolation types, rapid override is channel-specific.
10.3.3 Autonomous singleaxis operations
Functionality
Single PLC axes, command axes started via static synchronized actions or asynchronous
reciprocating axes can be interpolated independently of the NCK. An axis/spindle
interpolated by the main run then reacts independently of the NC program with respect to:
NC stop
Alarm handling
Program control
End of program
RESET
Extended Functions
Boundary conditions
Axes/spindles currently operating according to the NC program are not controlled by the
PLC.
Command axis movements cannot be started via non-modal or modal synchronized actions
for PLC-controlled axes/spindles. Alarm 20143 is signaled.
Transfer axis control to the PLC
Description of the sequence

1. PLC NCK: Request to control the axis
DB31, ... DBX28.7 = 1 (PLC controls axis)
2. NCK: Checks whether the axis is a main run axis or a neutral axis.
3. NCK: Checks whether an additional axis may be controlled from the PLC.
4. NCK confirms the transfer:
DB31, ... DBX63.1 = 1 (PLC controls the axis)
System variable $AA_SNGLAX_STAT = 1
Result: The PLC controls the axis/spindle.
Alternatives
Initial state: The axis is controlled by the PLC. As a result of a channel stop, the channel is in
the "interrupted" state.
Axis state "inactive"
The stop state is canceled.
If the axis is started, this directly results in axis motion.
Axis state "active"
The stop state is not canceled.
Generate the axis state according to Use case 2 "Stop axis".
Resume axis motion according to Use case 3 "Continue axis motion".
A reset is performed in the channel
This process is asynchronous to control acceptance by the PLC. The two previously
mentioned alternatives can occur or the axis is assigned to the channel and is reset.
Boundary conditions
Axes/spindles, traversed by an NC program, cannot be transferred to the PLC.
Axes/spindles, which are traversed by static synchronized actions or as oscillating axis, as
neutral axis, concurrent positioning axis or command axis, can be transferred.
Extended Functions
Relinquish axis control by the PLC

Description of the sequence:
1. PLC NCK: The PLC returns axis control to the NCK
2. NCK: Checks whether an axial alarm is present.
3. NCK: Checks whether a movement has been activated that has still not been completed?
If yes, then the movement is stopped with an axial stop according to Use case 2 "Stop
axis/spindle".
4. NCK: Carries out an axial reset corresponding to Use case 4 "Reset axis/spindle".
5. NCK confirms the acceptance:
DB31, ... DBX63.0 = 0 (reset executed)
DB31, ... DBX63.2 = 0 (axis stop active)
Result: The NCK has now taken over control of the axis/spindle.
Alternatives
In the following cases the NCK confirms the transfer - but internally sets the "stopped"
channel state for the axis/spindle:
The channel is in the "interrupted" state
A stop alarm is active for the channel
A stop alarm is active for the mode group
Boundary conditions
The axis/spindle must be operating under PLC control.
The NCK confirms acceptance of an axis/spindle only if an axial alarm is not active.
Description of the sequence based on use cases
Requirement
The axis/spindle is controlled by the PLC
Relevant NC/PLC interface signals

One of the axes/spindles controlled by the PLC can be influenced by the following NC/PLC
interface signals independent of the NC program:
For signal flow between the NCK and PLC at the NC/PLC interface during autonomous
single operations, see Section "Control by the PLC (Page 629)".
Extended Functions
Use case 1: Cancel axis/spindle

The behavior when canceling the axis/spindle function is the same as for "delete distance-to-
go":
DB21, ... DBX6.2 = 1 (delete distance-to-go)
Use case 2: Stop axis/spindle

The following traversing motion of the axis/spindle controlled from the main run is stopped:
PLC axis
Asynchronous oscillating axis
Command axis by static synchronized action
Overlaid motion: $AA_OFF,DRF handwheel traversal, online tool offset and external zero
offset.
Following axis movements of the axis/spindle are not stopped.
PLC NCK: Request to stop the axis/spindle
DB31, ... DBX28.6 = 1 (stop along braking ramp)
NCK: Brakes the axis along a ramp.
NCK confirms the execution:
DB31, ... DBX60.6 = 1 (exact stop coarse)
DB31, ... DBX60.7 = 1 (exact stop fine)
DB31, ... DBX64.6 / 7 = 0 (traversing command minus/plus)
Axis status interrupted with system variable $AA_SNGLAX_STAT == 3
Result: The axis/spindle is stopped.
Note
Following axis movements
Following axis movements can only be suppressed when the leading axis stops.
Retraction motion
Retraction motion triggered by the "Extended stop and retract" function cannot be stopped.
References
Function Description, Special Functions; Extended Stop and Retract (R3)
Extended Functions
Use case 3: Continue axis/spindle

Traversing motion interrupted after Use case 2 "Stop axis" should be continued.

PLC NCK: Continue axis
DB31, ... DBX28.2 = 1 (continue)
NCK: Checks whether for the axis/spindle an axial alarm with delete criterion
"CANCELCLEAR" or "NCSTARTCLEAR" is present? If yes, then this is deleted.
NCK: Checks whether axis motion can be resumed? If yes, then the axis/spindle makes
the transition into the "active" state.
DB31, ... DBX60.6 = 0 (exact stop coarse)
DB31, ... DBX60.7 = 0 (exact stop fine)
DB31, ... DBX64.6 / 7 = 1 (traversing command minus/plus)
Axis state active with system variable $AA_SNGLAX_STAT == 4.
Result: Traversing motion of the axis/spindle is continued.
Boundary conditions
In the following cases, the request to continue is ignored:
The axis/spindle is not controlled by the PLC.
The axis/spindle is not in the stopped state.
An alarm is pending for the axis/spindle.
Use case 4: Reset axis/spindle (reset)

PLC NCK: Reset request for this axis/spindle
DB31, ... DBX28.1 = 1 (reset)
NCK: Transitions the axis/spindle into the "stopped" state.
NCK: Interrupts the stopped sequences and signals to the PLC the interruption -
essentially the same as for "Delete distance-to-go".
NCK: The internal states for the axis/spindle are reset.
NCK: The axial machine data effective at reset becomes active.
Note
In contrast to a reset due to DB31, ... DBX28.1 = 1 (reset), in conjunction with a channel
reset, no axial machine data is active for axes controlled from the PLC.
Extended Functions

NCK: Ends this operation.
10.3.4 Autonomous single-axis functions with NC-controlled ESR
Extended stop numerically controlled

The numerically controlled extended stop and retract function is also available for single
axes and is configurable with axial machine data:
Delay time for ESR single axis with
MD37510 $MA_AX_ESR_DELAY_TIME1
ESR time for interpolatory braking of the single axis with
MD37511 $MA_AX_ESR_DELAY_TIME2
The values of these axial machine data are however effective only if the axis/spindle is a
single axis.
The NC-controlled extended stop and retract is activated by the axial trigger
$AA_ESR_TRIGGER[axis]. It works analogously to $AC_ESR_TRIGGER and applies
exclusively to single axes.
References:
Function Manual, Special Functions; Coupled axes and ESR (M3)
Extended Functions
Extended retract numerically controlled

For retracting single axes, the value must have been programmed via POLFA(axis, type,
value) and the following conditions must be met:
The axis must be a single axis at the time of triggering
$AA_ESR_ENABLE[axis]=1
POLFA(axis, type, value) with type=1 or type=2 only
POLFA(axis, value, axis, type, axis type).
Note
NC-controlled extended stop for single axes:
The trigger is only effective if the axis is a single axis at the time of triggering, otherwise
the trigger is ignored and the axial stop for this axis is not executed.
NC-controlled extended retract for single axes:
The channel-specific NC-controlled extended retract function is not effective for single
axes. All axes that are single axes at the time of triggering $AC_ESR_TRIGGER will be
ignored for channel-specific retraction.
This also applies when all the parameters for retraction are set, such as:
MD37500 $MA_ESR_REACTION
$AA_ESR_ENABLE for the axis, etc.
Examples
Extended stopping of a single axis:
MD37500 $MA_ESR_REACTION[AX1]=22
MD37510 $MA_AX_ESR_DELAY_TIME1[AX1]=0.3
MD37511 $MA_AX_ESR_DELAY_TIME2[AX1]=0.06
...
$AA_ESR_ENABLE[AX1] = 1
$AA_ESR_TRIGGER[AX1]=1 ; axis begins to stop the process here
Extended retraction of a single axis:
MD37500 $MA_ESR_REACTION[AX1]=21
...
$AA_ESR_ENABLE[AX1] = 1
POLFA(AX1, 1, 20.0); AX1 is assigned the axial retraction position 20.0 ; (absolute)
$AA_ESR_TRIGGER[AX1]=1 ; AX1 begins to retract here
POLFA(axis, type): permissible programming abbreviation
Extended Functions
10.4 Positioning axis dynamic response
POLFA(axis, 0/1/2) ; quick deactivation/activation
WARNING
No preprocessing limitation
If abbreviated notation is used and only the type is changed, make sure that the value for
the retraction position or retraction path in the application is meaningful!
The abbreviated notation should only be used in exceptional circumstances.
This particularly applies after:
A power on, the retraction path or the retraction position must be reset.
POLFA(axis, 1, $AA_POLFA[axis]) ; causes a preprocessing stop
POLFA(axis, 1); does not cause a preprocessing stop
Velocity
The positioning axes traverse at the axis-specific feedrate programmed for them. As
described under "Motion behavior and interpolation functions (Page 606)", this feedrate is
not influenced by the path axes.
The feedrate is programmed as an axis-specific velocity in units of min/mm, inch/min or
degrees/min.
The axis-specific feedrate is always permanently assigned to a positioning axis by the axis
name.
If a positioning axis has no programmed feedrate, the control system automatically applies
the rate set in axis-specific machine data:
The programmed axis-specific feedrate is active until the end of the program.
Feedrate override
The path and positioning axes have separate feedrate overrides. Each positioning axis can
be adjusted by its own axis-specific feedrate override.
Rapid traverse override

Rapid traverse override applies only to path axes. Positioning axes have no rapid traverse
interpolation (only axial linear interpolation G01) and therefore no rapid traverse override.
Extended Functions
Revolutional feedrate
In JOG mode the behavior of the axis/spindle also depends on the setting of SD41100
JOG_REV_IS_ACTIVE (revolutional feedrate when JOG active).
If this setting data is active, an axis/spindle is always moved with revolutional feedrate
MD32050 $MA_JOG_REV_VELO (revolutional feedrate with JOG) or MD32040
$MA_JOG_REV_VELO_RAPID (revolutional feedrate with JOG with rapid traverse
overlay) as a function of the master spindle.
If the setting data is not active, the behavior of the axis/spindle depends on SD43300
$SA_ASSIG_FEED_PER_REV_SOURCE (revolutional feedrate for positioning
axes/spindles)
If the setting data is not active, the behavior of a geometry axis on which a frame with
rotation is effective depends on the channel-specific setting data SD42600
$SC_JOG_FEED_PER_REV_SOURCE. (In the operating mode JOG, revolutional
feedrate for geometry axes on which a frame with rotation is effective.)
Maximum axial acceleration

With positioning axis motions, one of the two following maximum values is effective
depending on the set positioning axis dynamic response mode:
MD32300 $MA_MAX_AX_ACCEL [0] (maximum axial acceleration for path motions in the
dynamic response mode DYNNORM)
MD32300 $MA_MAX_AX_ACCEL [1] (maximum axial acceleration for path motions in the
dynamic response mode DYNPOS)
The positioning axis dynamic response mode is set in the NC-specific machine data:
<mode> Meaning
0 Effective maximum axial acceleration: MD32300 $MA_MAX_AX_ACCEL[ 0 ]
1 Effective maximum axial acceleration: MD32300 $MA_MAX_AX_ACCEL[ 1 ]
Maximum axial jerk

When traversing positioning axes with active jerk limitation, the value from one of the
following machine data takes effect as maximum axial jerk:
MD32430 $MA_JOG_AND_POS_MAX_JERK (maximum axial jerk for positioning axis
motions)
MD32431 $MA_MAX_AX_JERK [0] (maximum axial jerk for path motions in the dynamic
response mode DYNNORM)
MD32431 $MA_MAX_AX_JERK [1] (maximum axial jerk for path motions in the dynamic
response mode DYNPOS)
Extended Functions
10.5 Programming
The machine data to be used is determined by the set positioning axis dynamic response
mode:
<mode> Meaning
The following is effective as maximum axial jerk for positioning axis motions:
0 MD32430 $MA_JOG_AND_POS_MAX_JERK
With active G75 (fixed-point approach): MD32431 $MA_MAX_AX_JERK[0]
1 MD32431 $MA_MAX_AX_JERK[1]
10.5 Programming
10.5.1 General
Note
For the programming of position axes, please observe the following documentation:
References:
Programming Manual Basics; Section: "feed rate control" and "spindle motion"
Note
The maximum number of positioning axes that can be programmed in a block is limited to
the maximum number of available channel axes.
Definition
Positioning axes are defined using the following parameters:
Axis type: Positioning axis type 1, type 2 or type 3
End point coordinates (in absolute dimensions or in incremental dimensions)
Feedrate for linear axes in [mm/min], for rotary axes in [degrees/min]
Example: Positioning axis type 1

POS[Q1]=200 FA[Q1]=1000 ; Axis Q1 with feedrate 1000mm/min at Position 200.
Extended Functions
10.5 Programming
Example: Positioning axis type 2

POSA[Q2]=300 FA[Q2]=1500 ; Axis Q2 with feedrate 1,500mm/min at Position
300.
Note
Within a part program, an axis can be a path axis or a positioning axis. Within a movement
block, however, each axis must be assigned a unique axis type.
Programming in synchronized action

Axes can be positioned completely asynchronous to the part program from synchronized
actions.
Example:

ID=1 WHENEVER $R==1 DO POS[Q4]=10 FA[Q3]=990 ; The axial feedrate is specified
permanently.
References:
Block change
The block change can be adjusted for positioning axis types 1 and 2 with:
FINEA=<axis name> or
FINEA[<axis name>]
COARSEA=<axis name> or
COARSEA[<axis name>]
IPOENDA=<axis name> or
IPOENDA[<axis name>]
In Type 3 positioning axis, the block change within the brake ramp of the single interpolation
can be set with:
IPOBRKA=<axis name> or
IPOBRKA(<axis name>[,<instant in time*>])
* Instant in time of the block change, referred to the braking ramp as a %
Extended Functions
10.5 Programming
Absolute dimension / incremental dimension

The programming of the end point coordinates takes place in absolute dimension (G90) or in
incremental dimension (G91).
Example Meaning
Programming the end point coordinates
G90 POS[Q1]=200
In absolute dimension
G91 POS[Q1]=AC(200)
In absolute dimension
G91 POS[Q1]=200
In incremental dimension
G90 POS[Q1]=IC(200)
In incremental dimension
Reprogram type 2 positioning axes

With type 2 positioning axes (motion across block limits), you need to be able to detect in the
part program whether the positioning axis has reached its end position. Only then is it
possible to reprogram this positioning axis (otherwise an alarm is issued).
If POSA and then POSA again with IPOBRKA (block change in the braking ramp) is
programmed, an alarm is not issued. For more information, please refer to NC command
IPOBKA in Section "Settable block change time".
Coordination (WAITP)
The coordination command WAITP enables you to designate a position in the NC program
where the program is to wait until an axis programmed with POSA in a previous NC block has
reached its end position.
WAITP exists in an internal block.
An explicit reference must be made to any axis for which the program is to wait.
Example:

N10 G01 G90 X200 F1000 POSA[Q1]=200 FA[Q1]=500
N15 X400
N20 WAITP(Q1) ; The program processing is
stopped automatically until Q1
is at position.
N25 X600 POS[Q1]=300 ; Q1 is a positioning axis of
Type 1 (feedrate FA[Q1] from
block N10).
N30 X800 Q1=500 ; Q1 is path axis (path feed
F1000 from block N10).
Extended Functions
10.5 Programming
Tool offset
A tool length compensation for positioning axes can be implemented by means of an axial
zero offset, allowing, for example, the positioning path of a loader to be altered. An example
where the axial zero offset might be used in place of the tool length compensation is where a
loader containing tools of various dimensions has to bypass an obstacle.
End of program
The program end (program status selected) is delayed until all axes (path axes + positioning
axes) have reached their programmed end points.
10.5.2 Revolutional feed rate in external programming

The two following setting data can be used to specify that the revolutional feed rate of a
positioning axis should be derived from another rotary axis/spindle:
SD43300 $SA_ASSIGN_FEED_PER_REV_SOURCE(revolutional feed rate for position
axes/spindles)
SD42600 JOG_FEED_PER_REV_SOURCE (control of revolutional feed rate in JOG)
The following settings are possible:
Value Description
0 No revolutional feed rate selected
>0 The revolutional feed rate is derived from the round axis/spindle with the machine axis
index specified here.
-1 The revolutional feed rate is derived from the master spindle of the channel in which the
axis/spindle is active.
-2 The revolutional feed rate is derived from the rotary axis/spindle with the machine axis
index 0.
-3 The revolutional feed rate is derived from the master spindle of the channel in which the
axis/spindle is active. No revolutional feed rate is selected if the master spindle is at a
standstill.
Extended Functions
10.6 Block change
10.6 Block change

Since path and positioning axes are interpolated separately, they reach their programmed
end positions at different instants in time. If path and positioning axes are programmed in a
block together, then the block change behavior depends on the programmable type of
positioning axes.
Type 1: Block-related positioning axis

Properties:
The block change is performed as soon as all path and positioning axes have reached
their respective programmed end-of-motion criterion:
Path axes: G601, G602, G603
Positioning axes: FINEA, COARSA, IPOENDA
Programming the positioning axis: POS[<axis>]
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Note
Continuous path mode
Continuous path mode across block limits (G64) is only possible if the positioning axes reach
their end-of-motion criterion before the path axes (in the diagram above, this is not the case).
Extended Functions
10.6 Block change
Type 2: Modal positioning axis (across blocks)

Properties:
The block change is performed as soon as all path axes have reached their programmed
end-of-motion criterion (G601, G602, G603)
Programming the positioning axis: POSA[<axis>]
The positioning axis traverses beyond the block limits to its programmed end position. It
is not permissible that the positioning axis is programmed again before reaching its end-
of-motion criterion.
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Extended Functions
10.6 Block change
10.6.1 Settable block change time
Type 3: Conditional block-related positioning axis

Properties:
The block change is performed as soon as all path and positioning axes have reached
their respective programmed end-of-motion criterion:
Path axes: G601, G602, G603
Positioning axes: IPOBRKA
Programming the positioning axis:
N(x) IPOBRK(<axis>[,<instant in time>]) ;own block
N(x+1) POS[<axis>]
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Extended Functions
10.6 Block change
Block change criterion: "Braking ramp" (IPOBRKA)

If, when activating the block change criterion "brake ramp", a value is programmed for the
optional parameter <instant in time>, then this becomes effective for the next positioning
motion and is written into the setting data synchronized to the main run. If no value is
specified for the block change instant in time, then the actual value of the setting data is
effective.
SD43600 $SA_IPOBRAKE_BLOCK_EXCHANGE
The time at which the block change can be realized is specified as a percentage of the
braking ramp:
100% = start of the braking ramp
0% = end of the braking ramp, the same significance as block change criterion IPOENDA
Programming
IPOBRKA(<axis>[,<instant in time>])
IPOBRKA: Block change criterion: Deceleration ramp

Effective: Modal
<axis>: Channel axis name (X, Y, ....)
<instant in time>: Time of the block change, referred to the braking ramp as a %:
100% = start of the braking ramp
0% = end of the braking ramp, the same significance as
IPOENDA
Type: REAL
IPOBRKA is deactivated for the corresponding access when an axis end-of-motion criterion
(FINEA, COARSEA , IPOENDA ) is next programmed for the axis.
Additional block change criterion: "Tolerance window" (ADISPOSA)

A tolerance window around the end of block (either as actual or setpoint position) can be
defined as additional block change criterion. Then, two conditions must be fulfilled for the
block change:
Block change criterion: "Braking ramp"
Block change criterion: "Tolerance window"
Extended Functions
10.6 Block change
Programming
ADISPOSA(<axis>[,<mode>,<window size>])
ADISPOSA: Tolerance window for end-of-motion criterion

Effective: Modal
<axis>: Channel axis name (X, Y, ....)
<mode>: Reference of the tolerance window
Type: INT
Value range: 0 Tolerance window not active
1 Tolerance window with respect to the
setpoint position
2 Tolerance window with respect to actual
position
<window size>: Size of the tolerance window
Type: REAL
System variable for end-of-motion criterion

The effective end-of-motion criterion can be read using the system variable $AA_MOTEND.
References: Parameter Manual, Book 2
Note
Information about other programmable end-of-motion criteria FINEA, COARESA, IPOENDA can be
found in:
References: Function Manual, Basic Functions
Spindles (S1), Section "Spindle modes"
Feedrates (V1), Programmable dynamic response of single axis section
Premature block change

A premature block change is not possible in the following cases:
Oscillating axis
During oscillation with partial infeed, the block-specific oscillation motion must remain
active until the axis with partial infeed has reached its final position.
Handwheel
For handwheel input, the last set end-of-motion criterion applies.
Extended Functions
10.6 Block change
Changing the axis state

The axis for which a block change occurred within the braking ramp can only be
programmed in the following block in the same axis state.
When the axis state changes, e.g. to POSfollowed by SPOS, the last programmed end-of-
motion criterion FINEA, COARSEA, IPOENDA is active. This also applies in the following cases:
a positioning axis becomes a path axis
if the program waits for the end of the positioning movement: WAITP, M30, end of the
technology cycle, preprocessing stop
Velocity override is deactivated or activated
Note
For further information about programming positioning axes, see:
References:
Programming Manual, Fundamentals, Section "Feedrate control and spindle motion"
Programming Manual, Advanced, Section "Special motion commands"
Examples
Block change criteria "braking ramp" in the part program

; Default setting is effective.
N10 POS[X]=100 ; Positioning motion from X to position 100.
; Block change criterion: "Exact stop fine"
N20 IPOBRKA(X,100) ; Block change criterion: "Braking ramp", 100% = start of
the braking ramp.
N30 POS[X]=200 ; The block is changed as soon as the X axis starts to
brake.
N40 POS[X]=250 ; Axis X does not brake at position 200, but moves further
to position 250. As soon as the axis starts to brake, the
block is changed.
N50 POS[X]=0 ; Axis X brakes and returns to position 0,
the block change is realized at position 0 and "exact stop
fine".
N60 X10 F100 ; Axis X traverses as path axis to position 10.
N70 M30
Extended Functions
10.6 Block change
Block change criterion "braking ramp" in synchronized action

In the technology cycle:

FINEA ; End-of-motion criterion: "Exact stop fine"
N10 POS[X]=100 ; The technology cycle block change is realized if the X
axis has reached position 100 and "exact stop fine" is
reached.
N20 IPOBRKA(X,100) ; Block change criterion, activate "braking ramp",
100% = start of the braking ramp.
N30 POS[X]=200 ; The technology cycle block is changed as soon as the X
axis starts to brake.
block change is realized in the technology cycle.
fine".
N60 M17
Block change criterion "braking ramp" and "tolerance window" in the part program

; Default setting is effective.
N10 POS[X]=100 ; Positioning motion from X to position 100.
; Block change criterion: "Exact stop fine"
N20 IPOBRKA(X,100) ; Block change criterion: "Braking ramp", 100% = start of
the braking ramp.
N21 ADISPOSA(X,1,0.5) ; Tolerance window: 1 = setpoint position, tolerance = 0.5
N30 POS[X]=200 ; The block is changed as soon as the X axis starts to
brake.
block is changed.
fine".
N60 X10 F100
N70 M30
Extended Functions
10.6 Block change
Block change criterion "braking ramp" and "tolerance window" in synchronized action
In the technology cycle:

FINEA ; End-of-motion criterion: "Exact stop fine"
N10 POS[X]=100 ; The technology cycle block change is realized if the X
axis has reached position 100 and "exact stop fine" is
reached.
N20 IPOBRKA(X,100) ; Block change criterion, activate "braking ramp",100% =
start of the braking ramp.
N21 ADISPOSA(X,2,0.3) ; Tolerance window: 2 = actual position, tolerance = 0.3
N30 POS[X]=200 ; Technology cycle block change is realized as soon as the X
axis starts to brake and the actual position of the X axis
>= 199.7.
N40 POS[X]=250 ; X axis does not brake at position 200, but moves further
to position 250. As soon as the X axis starts to brake and
the position of the X axis >= 249.7, the block change is
realized in the technology cycle.
fine".
N60 M17
IPOBRKA(X) could also be written into the N20 blocks without specifying the instant in time, if
the corresponding value has already been entered into the setting data:
SD43600 $SA_IPOBRAKE_BLOCK_EXCHANGE[X] == 100
See also
Control by the PLC (Page 629)
10.6.2 End of motion criterion with block search
Last block serves as container

The last end-of-motion criterion programmed for an axis is collected and output in an action
block. The last block with a programmed motion end condition that was processed in the
search run serves as a container for setting all axes.
Extended Functions
10.7 Control by the PLC
Example
For two action blocks with end-of-motion criteria for three axes:

N01 G01 POS[X]=20 POS[Y]=30
IPOENDA[X] ; Last programmed IPOENDA end-of-motion
criterion
N02 IPOBRKA(Y, 50) ; Second action block for the Y axis
IPOENDA
N03 POS[Z]=55 FINEA[Z] ; Second action block for the Z axis
FINEA
N04 $A_OUT[1]=1 ; First action block for output as
digital output
N05 POS[X]=100 ;
N06 IPOBRKA(X, 100) ; Second action block for the X axis
IPOBRKA container
... ; For all programmed end-of-motion
criteria
TARGET: ; Block search target
The first action block contains the digital output:

$A_OUT[1] = 1.
The second action block contains the settings for the end-of-motion criteria:
for the X axis IPOBRKA / $SA_IPOBRAKE_BLOCK_EXCHANGE[AX1]=100
for the Y axis IPOBRKA / $SA_IPOBRAKE_BLOCK_EXCHANGE[AX2]=50
for the Z axis FINEA. The motion end condition IPOENDA last programmed is also stored for
the X axis.
PLC axes
PLC axes are traversed from the PLC and can move asynchronously to all other axes. The
travel motions are executed separate from the path and synchronized actions.
Reference:
Function Manual, Basic Functions; Basic PLC Program for SINUMERIK 840D sl (P3) or PLC
for SINUMERIK 828D (P4)
Concurrent positioning axes

Using function block FC18, for SINUMERIK 840D sl concurrent positioning axes can be
started from the PLC.
Extended Functions
Channel-specific signals
All channel-specific signals act to the same extent on path and positioning axes.
Only the following signals are an exception:
IS DB21, ... DBB4 ("Feedrate override")
IS DB21, ... DBX6.2 ("Delete distance to go")
Axisspecific signals
Positioning axes have the following additional signals:
IS DB31, ... DBX76.5 ("Positioning axis")
Feedrate for positioning axes/spindles (FA)
IS DB31, ... DBB0 ("Feedrate override") axis-specific
IS DB31, ... DBX2.2 ("Distance to go/Spindle reset") Axis-specific deletion of distance to
go
Single-axis functions of PLC-controlled axes

The behavior of individual PLC axes can be manipulated in the following way with machine
data:
MD30460 $MA_BASE_FUNCTION_MASK
:
Bit 4 = 1
The axis is exclusively controlled by the PLC.
Bit 5 = 1
The axis is a permanently assigned PLC axis.
Bit 6 = 1
The channel-specific NC/PLC interface signal:
DB21, ... DBX6.0 ("feed disable")
is not active for the axis if this is a PLC-controlled axis.
Bit 7= 1
The channel-specific NC/PLC interface signal:
DB21, ... DBX36.3 ("all axes stationary")
is setindependently of an axis if this is a PLC-controlled axis.
For a PLC-controlled axis:
The channel-specific NC/PLC interface signal DB21, ... DBX6.0 ("feed disable"), is active
if bit 6 = 0 in machine data MD30460 $MA_BASE_FUNCTION_MASK.
The channel-specific NC/PLC interface signal DB21, ... DBX36.3 ("all axes stationary") is
only set if bit 7 = 0 in machine data MD30460 $MA_BASE_FUNCTION_MASK.
If an attempt is made to assign an exclusively PLC-controlled axis to the NC program or to
request the axis for the NC program, then this is rejected with Alarm 26075. Alarm 26076 is
generated in the same way for a PLC axis with fixed assignment.
Extended Functions
A PLC axis with fixed assignment is a "neutral axis" on power up. For a travel request via the
NC/PLC interface, a concurrent positioning axis automatically changes to a PLC axis without
being interchanged beforehand.
Axis replacement via PLC

The type of an axis for axis replacement is transferred to the PLC with axial interface byte
NCKPLC NST DB31, ... DBB68 (see alsop Section "K5: Mode groups, channels, axis
interchange (Page 305)"):
IS DB31, ... DBX68.0-68.3 ("NC axis/spindle in channel") channels 1 to 10
IS DB31, ... DBX68.4 ("new type requested by PLC")
IS DB31, ... DBX68.5 ("axis can be replaced")
IS DB31, ... DBX68.6 ("neutral axis/spindle")
IS DB31, ... DBX68.7 ("PLC axis/spindle")
If IS DB31, ... DBX68.5 ("axis can be replaced") = 1, an axis replacement request can be
issued from the PLC.
10.7.1 Starting concurrent positioning axes from the PLC
Activation from PLC

When concurrent positioning axes are activated from the PLC, FC18 is called and supplied
with the following parameter data:
Axis name or axis number
End position
Feedrate (with feedrate setting = 0, the feedrate is determined by the setting in machine
data MD32060 $MA_POS_AX_VELO):
Absolute coordinate (G90),
incremental coordinate (G91),
absolute coordinate along the shortest path for rotary axes (rotary axis name =
DC(value))
The following functions are defined:
Linear interpolation (G01)
Feedrate in mm/min or degrees/min (G94)
Exact stop (G09)
Settable zero offsets currently selected are valid
Since each axis is assigned to exactly one channel, the control can select the correct
channel from the axis name/axis number and start the concurrent positioning axis on this
channel.
Extended Functions
10.7.2 PLC-controlled axes
PLC actions
The table below compares the following PLC actions with the corresponding NCK reactions
for a machine axis 1:
Start machine axis as PLC axis via FC 18
Initiate NC start or NC stop
Trigger axial STOP, RESUME or RESET

Trigger NC-RESET
Cancel or set controller enable for the machine axis
Relinquish control of machine axis to NC
Examples of NCK reactions

PLC actions are shown as NCK reactions in the table below.
PLC actions NCK reaction

Start machine AX1, residing in the 1st channel,
as PLC axis via FC 18
Initiate NC stop axes and spindles AX1 is stopped.
DB21, ... DBX7.4 = 1 (NC stop axes plus spindle)
DB21, ... DBX7.1 = 1 initiate (NC start) AX1 continues to traverse.
PLC wants to control AX1, Checking AX1 is relinquished to the PLC. DB31,
DB31, ... DBX28.7 = 1 (PLC controls axis) ... DBX63.1 = 1 (PLC controls the axis)
Initiate NC stop for axes and spindles AX1 is not stopped.
DB21, ... DBX7.4 = 1 ("NC stop axes plus
spindle")
Initiate axial stop AX1 is stopped
DB31, ... DBX28.6 = 1 (stop along braking ramp) DB31, ... DBX63.2 ==1 (axis stop active)
Initiate that axial movement continues AX1 moves further
DB31, ... DBX28.2 = 1 (continue) DB31, ... DBX63.2 == 0 (axis stop active)
Initiate NC-RESET No effect on AX1
DB21, ... DBX7.7 = 1 initiate (reset)
Initiate axial reset AX1 is stopped and the traversing motion is
DB31, ... DBX28.1 = 1 (reset) interrupted:
Read-in axial machine data
Extended Functions
PLC actions NCK reaction

Start machine axis AX1 as PLC axis via DB31, ... DBX63.0 = 0 (reset executed)
FC 18
Withdraw controller enable for AX1: Alarm 21612 "Axis %1 measuring system
DB31, ... DBX2.1 = 0 (controller enable) change" is displayed
Initiate that axial movement continues Alarm 21612 "Axis %1 measuring system
DB31, ... DBX28.2 = 1 (continue) change" is deleted
DB21, ... DBX40.7 = 1(traversing command
plus)
AX1 does not traverse due to a missing
controller enable signal.
Set controller enable for AX1 AX1 moves to the programmed end point.
DB31, ... DBX2.1 = 1 (controller enable)
Initiate axial reset Stop AX1
DB31, ... DBX28.1 = 1 (reset)
Read-in axial machine data
DB31, ... DBX63.0 = 0 (reset)
PLC relinquishes control of AX1 to the NCK from NCK accepts control of machine axis
DB31, ... DBX63.0 = 0 (reset)
10.7.3 Control response of PLC-controlled axes
Response to channel reset, NEWCONFIG, block search and MD30460
Control response to PLC-controlled axis

Mode change and NC program control work independently of axis.
Channel RESET No axial machine data are effective and a
traversing movement is not aborted.
NEWCONFIG No axial machine data are effective.
Block search Type 5 SERUPRO are processed during SERUPRO to simulate the
normal procedure, e.g. PLC takes over or
relinquishes control of this axis which is also
traversing via the PLC.
All block search variants The PLC takes over control of the axis before the
of types 1, 2, 4 and 5 approach block and is responsible for positioning
this axis.
NC-controlled retraction activated with has no effect and acts only on the specified PLC-
$AC_ESR_TRIGGER. controlled axis.
Extended Functions
Control response to PLC-controlled axis

machine data: which is not controlled
MD30460 $MA_BASE_FUNKTION_MASK exclusively by the PLC
Bit 4 = 0 cannot be changed directly with axis replacement
command GET (axis) or AXTOCHAN(axis,
channel) to an axis controlled by the NC program,
see * Note on axis replacement.
Bit 4 = 1 cannot be requested for the NC program. GET or
AXTOCHAN from the NC program or a
synchronized action, or programming the axis in
the NC program, are rejected with alarm 26075.
MD30460 $MA_BASE_FUNKTION_MASK For the PLC-controlled axis
Bit 6 = 1 channel-specific
IS DB 21, ... DBX6.0 ("feed disable") is not
effective. This axis is not stopped when feed
disable is activated, but continues to move.
Bit 7 = 1 the axis is not taken into account when
IS DB 21, ... DBX36.3 ("all axes stationary") is
generated. This signal is output with 1 even if all
other axes in the channel are stationary and only
the PLC-controlled axis is active.
* Note on axis replacement

This replacement of a "neutral axis" by an "NC program axis" does not take place until the
PLC has really relinquished control of the axis in accordance with use case "Relinquish
control of axis". Waiting for this axis interchange is displayed on the HMI operator panel
front.
Extended Functions
10.8 Response with special functions
10.8 Response with special functions
10.8.1 Dry run (DRY RUN)

The dry run feedrate is also effective for positioning axes unless the programmed feedrate is
larger than the dry run feedrate.
Activation of the dry run feed entered in SD42100 $SA_DRY_RUN_FEED can be controlled
with SD42101 $SA_DRY_RUN_FEED_MODE. See
References:
10.8.2 Single block
Positioning axis type 1

Single-block mode is effective with positioning axes of type 1.

Positioning axes of type 2 also continue across block limits in single block mode.

Positioning axes of type 3 also continue across block limits in single block mode.
Extended Functions
10.9 Examples
10.9 Examples
10.9.1 Motion behavior and interpolation functions

In the following example, the two positioning axes Q1 and Q2 represent two separate units
of movement. There is no interpolation relationship between the two axes. In the example,
the positioning axes are programmed as type 1 (e.g. in N20) and type 2 (e.g. in N40).
Program example
Program code
N10 G90 G01 G40 T0 D0 M3 S1000
N20 X100 F1000 POS[Q1]=200 POS[Q2]=50 FA[Q1]=500
FA[Q2]=2000
N30 POS[Q2]=80
N40 X200 POSA[Q1] = 300 POSA[Q2]=200] FA[Q1]=1500
N45 WAITP[Q2]
N50 X300 POSA[Q2]=300
N55 WAITP[Q1]
N60 POS[Q1]=350
N70 X400
N75 WAITP[Q1, Q2]
N80 G91 X100 POS[Q1]=150 POS[Q2]=80
N90 M30
4
4
111111111
;SDWKD[HV
44SRVLWLRQLQJD[HV
Figure 10-4 Timing of path axes and positioning axes
Extended Functions
10.10 Data lists
10.9.1.1 Traversing path axes without interpolation with G0
Example in G0 for positioning axes

Path axes traverse as positioning axes with no interpolation in rapid traverse mode (G0):

; Activation of nonlinear
; Interpolation
; MD20730 $MC_GO_LINEAR_MODE == FALSE
; is set
G0 X0 Y10 ; axis traverses without interpolation
G0 G43 X20 Y20 ; axis traverses in path mode (with
interpolation)
; Traversing
G0 G64 X30 Y30 ; axis traverses in path mode (with
interpolation)
; Traversing
G0 G95 X100 Z100 m3 s100 ; axis traverses without interpolation
; no revolutional feedrate active
10.10 Data lists
10.10.1 Machine data
10.10.1.1 NC-specific machine data

18960 POS_DYN_MODE Type of positioning axis dynamic response

20730 G0_LINEAR_MODE Interpolation behavior with G0
20732 EXTERN_G0_LINEAR_MODE Interpolation behavior with G00
22240 AUXFU_F_SYNC_TYPE Output timing of F functions
Extended Functions
10.10 Data lists

30450 IS_CONCURRENT_POS_AX Concurrent positioning axis
30460 BASE_FUNCTION_MASK Axis functions
32060 POS_AX_VELO Feedrate for positioning axis
32300 MAX_AX_ACCEL Maximum axis acceleration
32430 JOG_AND_POS_MAX_JERK Maximum axial jerk for positioning axis movements
32431 MAX_AX_JERK Maximum axial jerk for path movements
37510 AX_ESR_DELAY_TIME1 Delay time for ESR single axis
37511 AX_ESR_DELAY_TIME2 ESR time for interpolatory braking of single axis
10.10.2 Setting data

43600 IPOBRAKE_BLOCK_EXCHANGE Braking ramp block change condition
43610 ADISPOSA_VALUE Braking ramp tolerance window
10.10.3 Signals

feed disable DB21, ... .DBX6.0 DB3200.DBX6.0
NC Start DB21, ... .DBX7.1 DB3200.DBX7.1
NC stop axes plus spindle DB21, ... .DBX7.4 DB3200.DBX7.4
Reset DB21, ... .DBX7.7 -
Extended Functions
10.10 Data lists

All axes stationary DB21, ... .DBX36.3 DB3300.DBX4.3
Travel command minus DB21, ... .DBX40.6 DB3300.DBX1000.6
Travel command plus DB21, ... .DBX40.7 DB3300.DBX1000.7

Feedrate override, axis-specific DB31, ... .DBB0 DB380x.DBB0
Controller enable DB31, ... .DBX2.1 DB380x.DBX2.1
Delete distance-to-go spindle reset for specific axes DB31, ... .DBX2.2 DB380x.DBX2.2
Reset DB31, ... .DBX28.1 -
Continue DB31, ... .DBX28.2 -
Stop along braking ramp DB31, ... .DBX28.6 -
PLC-controlled axis DB31, ... .DBX28.7 -

Exact stop coarse DB31, ... .DBX60.6 DB390x.DBX0.6
Exact stop fine DB31, ... .DBX60.7 DB390x.DBX0.7
Axial alarm DB31, ... .DBX61.1 DB390x.DBX1.1
Axis ready (AX_IS_READY) DB31, ... .DBX61.2 DB390x.DBX1.2
Axis container rotation active DB31, ... .DBX62.7 -
AXRESET DONE DB31, ... .DBX63.0 -
Axis stop active DB31, ... .DBX63.2 DB390x.DBX3.2
Travel command minus DB31, ... .DBX64.6 DB390x.DBX4.6
Travel command plus DB31, ... .DBX64.7 DB390x.DBX4.7
Positioning axis DB31, ... .DBX76.5 DB390x.DBX1002.5
F function (feedrate) for positioning axis DB31, ... .DBB78-81 -
Emergency retraction active DB31, ... .DBX98.7 DB390x.DBX5002.7
Extended Functions
10.10 Data lists
Extended Functions
P5: Oscillation - only 840D sl 11
Definition
When the "Oscillation" function is selected, an oscillation axis oscillates backwards and
forwards at the programmed feedrate or a derived feedrate (revolutional feedrate) between
two reversal points. Several oscillation axes can be active at the same time.
Oscillation variants
Oscillation functions can be classified according to the axis response at reversal points and
with respect to infeed:
Asynchronous oscillation across block boundaries
During reciprocating movement, other axes can interpolate at will. The oscillation axis can
act as the input axis for dynamic transformation or as the master axis for gantry or
coupled-motion axes. Oscillation is not automatically linked to the AUTOMATIC mode.
Oscillation with continuous infeed.
Simultaneous infeed in multiple axes is possible. However, there is no interpolative
connection between the infeed and oscillation movements.
Oscillation with infeed in both reversal points or only in the left-hand or right-hand
reversal point. The infeed can be initiated at a programmable distance from the reversal
point.
Sparking-out strokes after oscillation.
Beginning and end of oscillation at defined positions.
Response at reversal points

The change in direction is initiated:
without the exact stop limit being reached (exact stop fine or coarse)
After reaching the programmed position or
after the programmed position is reached and expiry of a dwell.
by an external signal (from the PLC).
Extended Functions
P5: Oscillation - only 840D sl
11.2 Asynchronous oscillation
Control methods
Oscillation movements can be controlled by various methods:
The oscillation movement and/or infeed can be interrupted by delete distance-to-go.
The reversal points can be altered via NC program, PLC, HMI, handwheel or directional
keys.
The feedrate velocity of the oscillation axis can be altered through a value input in the NC
program, PLC, HMI or via an override. The feedrate can be programmed to be dependent
on a master spindle, rotary axis or spindle (revolutional feedrate).
References:
The oscillation movement can be controlled entirely by the PLC.
Methods of oscillation control

There are two modes of oscillation:
1. Asynchronous oscillation:
Is active across block boundaries and can also be started from the PLC/HMI.
2. Oscillation by synchronized movement actions:
In this case the asynchronous oscillation and an infeed movement are coupled via
synchronized actions. In this way, it is possible to program oscillation with infeed at the
reversal points which is active on a non-modal basis.
Characteristics
The characteristics of asynchronous oscillation are as follows:
The oscillation axis oscillates backwards and forwards between reversal points at the
specified feedrate until the oscillation movement is deactivated or until there is an
appropriate response to a supplementary condition. If the oscillation axis is not positioned
at reversal point 1 when the movement is started, then it traverses to this point first.
Linear interpolation G01 is active for the oscillation axis regardless of the G code
currently valid in the program. Alternately, revolutional feedrate G95 can be activated.
Asynchronous oscillation is active on an axis-specific basis beyond block limits.
Several oscillation axes (i.e. maximum number of positioning axes) can be active at the
same time.
Extended Functions
During the oscillation movement, axes other than the oscillation axis can be freely
interpolated. A continuous infeed can be achieved via a path movement or with a
positioning axis. In this case, however, there is no interpolative connection between the
oscillation and infeed movements.
If the PLC does not have control over the axis, then the axis is treated like a normal
positioning axis during asynchronous oscillation. In the case of PLC control, the PLC
program must ensure via the appropriate stop bits of the NC/PLC interface that the axis
reacts in the desired way to NC/PLC interface signals. These NC/PLC interface signals
also include end of program, operating mode change and single block.
The oscillation axis can act as the input axis for the transformations (e.g. inclined axis,
see Section "M1: Kinematic transformation (Page 347)").
The oscillation axis can act as the master axis for gantry and coupled motion axes.
References:
Function Manual, Special Functions; Gantry Axes (G1)
It is possible to traverse the axis with jerk limitation (SOFT) and/or with kneeshaped
acceleration characteristic (as for positioning axes).
In addition to this, the oscillation movement can be activated in synchronism with the
block via the part program.
The oscillation movement can likewise be started, influenced and stopped from the
PLC/HMI.
Interpolatory oscillation is not possible (e.g. oblique oscillation).
11.2.1 Influences on asynchronous oscillation
Setting data
The setting data required for oscillation can be set with special language commands in the
NCK part program, via the HMI and/or the PLC.
Feedrate
The feed velocity for the oscillation axis is selected or programmed as follows:
The velocity defined for the axis as a positioning axis is used as the feed velocity. This
value can be programmed via FA[axis] and has a modal action. If no velocity is
programmed, then the value stored in machine data POS_AX_VELO is used (see also
Section "P2: Positioning axes (Page 599)").
When an oscillation movement is in progress, the feed velocity of the oscillation axis can
be altered via setting data. It can be specified via the part program and setting data
whether the changed velocity must take effect immediately or whether it should be
activated at the next reversal point.
Extended Functions
The feedrate can be influenced by the override (axial NC/PLC interface signal and
programmable).
If Dry Run is active, the dry run velocity setting is applied if it is higher than the currently
programmed velocity.
Activation of the dry run feed entered in SD42100 $SC_DRY_RUN_FEED can be
controlled with SD42101 $SC_DRY_RUN_FEED_MODE.
References:
The velocity overlay / path overlay can be influenced by the handwheel (see following
table and Section "H1: Manual and handwheel travel (Page 143)").
The oscillation axis can be moved with reversal feed.
Reversal feed
The reversal feed can also be used for oscillation axes.
Reversal points
The positions of the reversal points can be entered via setting data before an oscillation
movement is started or while one is in progress.
The reversal point positions can be entered by means of manual travel (handwheel, JOG
keys) before or in the course of an oscillation movement, regardless of whether the
oscillation movement has been interrupted or not.
The following applies to alteration of a reversal point position: When an oscillation movement
is already in progress, the altered position of a reversal point does not become effective until
this point is approached again. If the axis is already approaching the position, the correction
will take effect in the next oscillation stroke.
Note
If a reversal point must be altered at the same time as NC/PLC interface signal DB21,
DBX0.3 ("Activate DRF") is set, the handwheel signals are applied both to the DRF offset
and to the offset of the reversal point, i.e. the reversal point is shifted absolutely by an
amount corresponding to twice the distance.
Stop times
A stop time can be programmed via setting data for every reversal point.
The setting can be changed in the following blocks of the NC program. It is then effectively
block synchronous from the next reversal point.
Stop time can be changed asynchronously via setting data. It is then effective from the
instant that the appropriate reversal point is next traversed.
Extended Functions
The following table explains the motional behavior in the exact stop range or at the reversal
point, depending on the stop time input.
Table 11- 1 Effect of stop time
Stop time setting Response

-2 Interpolation continues without wait for exact stop
-1 Wait for coarse exact stop at reversal point
0 Wait for fine exact stop at reversal point
>0 Wait for fine exact stop at reversal point, followed by wait for stop time.
Deactivate oscillation
One of the following options can be set for termination of the oscillation movement when
oscillation mode is deactivated:
Termination of oscillation movement at the next reversal point
Termination of oscillation movement at reversal point 1
Termination of oscillation movement at reversal point 2
Following this termination process, sparking-out strokes are processed and an end position
approached if programmed.
On switchover from asynchronous oscillation to spark-out and during spark-out, the
response at the reversal point regarding exact stop corresponds to the response determined
by the stop time programmed for the appropriate reversal point. A sparking-out stroke is the
motion to the other reversal point and back (see the table below):
Note
Oscillation with motion-synchronous actions and stop times "OST1/OST2"
Once the set stop times have expired, the internal block change is executed during
oscillation (indicated by the new distances-to-go of the axes). The deactivation function is
checked when the block changes. The deactivation function is defined according to the
control setting for the motional sequence "OSCTRL".
This dynamic response can be influenced by the feed override.
An oscillation stroke may then be executed before the sparking-out strokes are started or the
end position approached.
Although it appears as if the deactivation response has changed, this is not in fact the case.
Extended Functions
Table 11- 2 Operational sequence for deactivation of oscillation
Function Inputs Explanation

Deactivation at defined reversal Number of sparking-out strokes The oscillation movement is
point equals 0, stopped at the appropriate
no end position active reversal point
Deactivation with specific Number of sparking-out strokes After the appropriate reversal
number of sparking-out strokes is not equal to 0, point is reached, the number of
no end position is active sparking-out strokes specified in
the command are processed.
Deactivation with sparking-out Number of sparking-out strokes After the appropriate reversal
strokes and defined end position is not equal 0 point is reached, the number of
(optional) end position active sparking-out strokes specified in
the command are processed,
followed by approach to
specified end position.
Deactivation without sparking- Number of sparking-out strokes After the appropriate reversal
out strokes, but with defined end is equal 0 point is reached, the axis is
position (optional) end position active traversed to the specified end
position.
NC language
The NC programming language allows asynchronous oscillation to be controlled from the
part program. The following functions allow asynchronous oscillation to be activated and
controlled as a function of NC program execution.
Note
If the setting data is directly written in the part program, then the data change takes effect
prematurely with respect to processing of the part program (at the preprocessing time). It is
possible to re-synchronize the part program and the oscillation function commands by
means of a preprocessing stop (STOPRE).
References:
Programming Guide
1) Activate, deactivate oscillation:
OS[oscillation axis] = 1; Activate oscillation for oscillation axis
OS[oscillation axis] = 0; Deactivate oscillation for oscillation axis
Note
Every axis may be used as an oscillation axis.
Extended Functions
2) End of oscillation:
WAITP(oscillation axis)
Positioning axis command stops block until oscillation axis is at fine stop and
synchronizes preprocessing and main run. The oscillation axis is entered as positioning
axis again and can then be used normally.
If an axis is to be used for oscillation, it must be released with a WAITP(axis) command
beforehand.
This also applies if oscillation is initiated from the PLC/HMI. In this case, the WAITP(axis)
call is also needed if the axis was programmed beforehand via the NC program. As of
SW version 3.2 it is possible to select via machine data $MA_AUTO_GET_TYPE,
whether WAITP() shall be performed with programming or automatically.
Note
WAITP effectively implements a time delay until the oscillation movement has been
executed. Termination of the movement can be initiated, for example, through a
programmed deactivation command in the NC program or via the PLC or HMI by means
of deletion of distance-to-go.
3) Setting reversal points:

OSP1[oscillation axis] = position of reversal point 1
OSP2[oscillation axis] = position of reversal point 2
A position is entered into the appropriate setting data in synchronism with the block in the
main run and thus remains effective until the setting data is next changed.
If incremental traversal is active, then the position is calculated incrementally to the last
appropriate reversal point programmed in the NC program.
4) Stopping times at reversal points:
OST1[oscillation axis] = stop time at reversal point 1 in [s]
OST2[oscillation axis] = stop time at reversal point 2 in [s]
A stop time is entered into the appropriate setting data in synchronism with the block in the
main run and thus remains effective until the setting data is next changed.
The unit for the stop time is identical to the unit selected for the stop time programmed with
G04.
5) Setting feedrate:
FA[axis] = FValue
Positioning axis infeed.
The feedrate is transferred to the appropriate setting data in synchronism with the block in
the main run. If the oscillation axis is moved with reversal feed, the corresponding
dependencies must be indicated as described in Description of Functions V1.
Extended Functions
6) Setting control settings for sequence of movements:

OSCTRL[oscillating axis] = (set options, reset options)
The set options are defined as follows (the reset options deselect the settings):
Table 11- 3 Set/reset options
Option value Meaning

0 Stop at next reversal point on deactivation of the oscillation movement (default).
Can only be achieved by resetting option values 1 and 2.
1 Stop at reversal point 1 on deactivation of the oscillation movement
2 Stop at reversal point 2 on deactivation of the oscillation movement
3 On deactivation of oscillation movement, do not approach reversal point unless
sparking-out strokes are programmed
4 Approach an end position after spark-out process
8 If the oscillation movement is aborted by delete distance-to-go, the sparking-out
strokes must then be executed and the end position approached (if programmed)
16 If the oscillation movement is terminated by deletion of distance-to-go, the
programmed reversal point must be approached on deactivation of the oscillation
movement.
32 Altered feedrate will only take effect from the next reversal point.
64 If feedrate setting is 0, path overlay is active, or otherwise velocity overlay
128 For rotary axis DC (shortest path)
256 Sparking-out stroke as single stroke
512 First approach start position
Note
The option values 0-3 encode the behavior at reversal points at Power OFF. You can choose
one of the alternatives 0-3. The other settings can be combined with the selected alternative
according to individual requirements. A + character can be inserted to create a string of
options.
Example: The oscillation movement for axis Z must stop at reversal point 1 on deactivation;
an end position must then be approached and a newly programmed feedrate take immediate
effect; the axis must stop immediately after deletion of distance-to-go.
OSCTRL[Z] = (1+4, 16+32+64)
The set/reset options are entered into the appropriate setting data in synchronism with the
block in the main run and thus remain effective until the setting data is next changed.
Note
The control evaluates the reset options, then the set options.
Extended Functions
7) Sparking-out strokes:
OSNSC[oscillation axis] = number of sparking-out strokes
The number of sparking-out strokes is entered into the appropriate setting data in
synchronism with the block in the main run and thus remains effective until the setting data is
next changed.
8) End position to be approached after deactivation of oscillation:
OSE[oscillation axis] = end position of oscillation axis
The end position is entered into the appropriate setting data in synchronism with the block in
the main run and thus remains effective until the setting data is next changed. Option value 4
is implicitly set so that the set end position is approached.
9) Start position to be approached prior to activation of oscillation:
OSB [oscillation axis] = start position of oscillation axis
The start position is entered into the appropriate setting data SD43790
$SA_OSCILL_START_POS in synchronism with the block in the main run and thus remains
effective until the setting data is next changed. Bit 9 in setting data SD43770
$SA_OSCILL_CTRL_MASK must be set to initiate an approach to the start position. The
start position is approached before reversal point 1. If the start position coincides with
reversal position 1, reversal position 2 is approached next.
As an alternative to programming command OSB, it is also possible to enter the start
position directly in setting data SD43790 $SA_OSCILL_START_POS.
All positional information in the setting data and system variables refer to the basic
coordinate system (BCS). The positional data for OSB, OSE refer to the workpiece
coordinate system (WCS).
No halt time applies when the start position is reached, even if this position coincides with
reversal position 1; instead, the axis waits for the exact stop fine signal. Any configured exact
stop condition is fulfilled.
If a non-modal oscillation process does not require an infeed motion if the start position
coincides with reversal position 1, this option can be configured with another synchronized
action (see Section "Non-modal oscillation (starting position = reversal point 1) (Page 673)").
Programming example
An example that contains all the important elements for asynchronous oscillation can be
found in Section "Example of asynchronous oscillation (Page 666)".
Extended Functions
11.2.2 Asynchronous oscillation under PLC control
Activation
The function can be selected from the PLC using the following setting data in all operating
modes except for MDA Ref and JOG Ref.:
SD43780 OSCILL_IS_ACTIVE (switch-on oscillation motion)
Settings
The following criteria can be controlled from the PLC via setting data: Activation and
deactivation of oscillation movement, positions of reversal points, stop times at reversal
points, feedrate velocity, the options in the reversal points, the number of sparking-out
strokes and the end position after deactivation. However, these values can also be set
beforehand as a setting data via the HMI user interface directly or via an NC program. These
settings remain valid after power ON and the PLC can also start an oscillation movement set
in this way directly via setting data OSCILL_IS_ACTIVE (via variable service).
A spindle which must act as an axis to execute an oscillation movement started via the PLC
must fulfill the conditions required to allow traversal as a positioning axis, i.e. the spindle
must, for example, have been switched to the position control (SPOS) beforehand.
The axes always respond to the following two stop bits - regardless of whether the axis is
controlled from the PLC or not:
DB31, ... DBX28.5 (stop at the next reversal point)
11.2.3 Special reactions during asynchronous oscillation
With PLC control

The PLC program can assume the control of an oscillation axis via NC/PLC signals. The
NC/PLC interface signals also include end of program, operating mode change and single
block.
Using the NCU system software, an asynchronous reciprocating axis interpolated by the
main run reacts to NC STOP, alarm handling, end of program, program control and RESET.
The PLC controls the axis/spindle via the axial NC/PLC interface (PLCNCK) by means of
IS DB31, ... DBX28.7 (PLC controlled axis) = 1
For further information about axes with PLC control, see Section "P2: Positioning axes
(Page 599)".
Extended Functions
Without PLC control

If the PLC does not have control over the axis, then the axis is treated like a normal
positioning axis (POSA) during asynchronous oscillation.
Delete distance-to-go
Channel-specific delete distance-to-go is ignored.
Axial delete distance-to-go
Without PLC control: Stop via braking ramp
With PLC control: No stop (must be initiated from the PLC)
The following applies to both cases: After the axis is stopped, if necessary, the appropriate
reversal point is approached and the distance-to-go deleted. The sparking-out strokes are
then executed and the end position approached. Provided this has been set in
OSCILL_CTRL_MASK.
The oscillation movement is then completed.
Note
During grinding, the calipers can be put into action via axial delete distance-to-go.
Emergency stop
The emergency stop completes the oscillation movement that must be restarted.
Reset
The oscillation movement is interrupted and deselected with a braking ramp. The options
selected subsequently are not processed (sparking-out strokes, end point approach).
Working area limitation, limit switches

If it is detected during preprocessing that the oscillation movement would violate an active
limitation, then an alarm is output and the oscillation movement not started.
If during an active oscillation movement the oscillation axis overtravels a limitation which has
been activated in the meantime (e.g. 2nd software limit switch), then the axis is decelerated
down along a ramp and an alarm indicated.
CAUTION
Protection areas
No protection areas act for a oscillation movement.
Extended Functions
Follow-up mode
There is no difference to positioning axes.
End of program
If the axis is not controlled by the PLC, then the program end is not reached until the
oscillation movement is terminated (reaction as for POSA:
Positioning across block boundaries).
If the axis is controlled by the PLC, then it continues to oscillate after program end.
Mode change
The following table shows the operating modes in which oscillation can be implemented.
Changeover to an operating mode which allows oscillation does not affect the oscillation
movement. Changeover to inadmissible operating modes is rejected with an alarm. It is not
possible to traverse an axis in oscillation mode while applying control commands from the
NC program or via operator inputs (JOG) simultaneously; an alarm is output if this is
attempted. The following applies: The type of movement first started has priority.
Table 11- 4 Operating modes which allow oscillation
Operating mode Allows oscillation

AUTO Yes
MDA Yes
MDA Repos Yes
MDA Teachin Yes
MDA Ref No
JOG Yes
JOG Ref No
JOG Repos Yes
Single-block processing
If the axis is not controlled by the PLC, then it responds to a single block in the same way as
a positioning axis (POSA), i.e. it continues the movement.
Override
The override is specified by the:
NC/PLC interface
Axial override acts on the oscillation axis.
Programming
The override acts on oscillation axes in the same way as on positioning axes.
Extended Functions
11.3 Oscillation controlled by synchronized actions
Block search
In Block Search the last valid oscillation function is registered and the machine data
OSCILL_MODE_MASK is activated (default) accordingly, either directly after NC start (when
approaching the start position after block search) or after reaching the start position after
block search.
OSCILL_MODE_MASK Bit 0:
0: Oscillation starts after reaching the start position.
1: Oscillation starts immediately after NC start.
REORG
Reversal point 1 is always approached first before oscillation continues.
ASUB
The oscillation movement continues while an ASUB (asynchronous subprogram) is in
progress.
General procedure
An asynchronous oscillation movement is coupled via synchronized actions with an infeed
motion and controlled accordingly.
References:
The following description concentrates solely on the motion-synchronous actions associated
with the oscillation function.
Functions
The following function complexes can be implemented by means of the language tools
described in detail below:
1. Infeed at the reversal point (see Section "Infeed at reversal point 1 or 2 (Page 656)").
2. Infeed at the reversal point range (see Section "Infeed in reversal point range
(Page 657)").
3. Infeed in both reversal points (see Section "Infeed at both reversal points (Page 659)").
4. Stop the oscillation movement at the reversal point until infeed is terminated (see Section
"Stop oscillation movement at the reversal point (Page 660)").
5. Enable oscillation movement (see Section "Oscillation movement restarting (Page 661)").
Extended Functions
6. Do not start partial infeed too early (see Section "Do not start partial infeed too early
(Page 662)").
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Figure 11-1 Arrangement of oscillation and infeed axes plus terms
Legend:
U1: Reversal point 1
U2: Reversal point 2
ii1: Reversal point range 1
ii2: Reversal point range 2
Programming
Before the motion block that contains the assignment between the infeed and the oscillating
axis (see Section "Assignment of oscillation and infeed axes OSCILL (Page 662)"), the
infeed definition (POSP) and the motion-synchronous actions, the parameters for the
oscillation must first be defined (see Section "Influences on asynchronous oscillation
(Page 643)"):
The oscillation axis is enabled via a WAITP [oscillation axis] (see MD30552
$MA_AUTO_GET_TYPE), allowing the oscillation parameters to be transferred, i.e. into the
setting data, simultaneously. The symbolic names, e.g. SA43700 $SA_REVERSE_POS1
can then be used to program the motion-synchronous actions.
Note
For motion-synchronous actions with $SA_REVERSE_POS values, the comparison values
at the time of interpretation are valid. If setting data is changed afterwards, this has no
effect.
For motion-synchronous actions with $AA_REVERSE_POS values, the comparison values
within the interpoltation are valid. This ensures a reaction to the modified reversal positions.
Extended Functions
Motion-synchronous conditions WHEN, WHENEVER

Activation through motion block
Assign oscillation axis and infeed axes to one another OSCILL
Specify infeed response POSP.
The following sections present those elements which have not yet been dealt with.
Some examples are described in the "Examples" section.
Note
If the condition with which the motion-synchronous action (WHEN and WHENEVER) has
been defined is no longer valid, the OVERRIDE for this condition is automaticallyset to 100%
if the OVERRIDE had been set to 0% before.
Main run evaluation

It is possible to compare the synchronization conditions in the interpolation cycle in the main
run with the current actual values ($$ variable on the right of comparison conditions). With
normal system variable comparison, the expressions are evaluated in the first run. The
complete extended possibilities for synchronized actions are listed in the following
documentation:
References:
Example 1
Oscillation, reversal position firmly set via setting data:

$SA_OSCILL_REVERSE_POS1[Z]=-10
$SA_OSCILL_REVERSE_POS2[Z]=10
G0 X0 Z0
WAITP(Z)
ID=1 WHENEVER $AA_IM[Z] <
$SA_OSCILL_REVERSE_POS1[Z] DO
$AA_OVR[X]=0
ID=2 WHENEVER $AA_IM[Z] > ; If the actual value of the oscillation axis
$SA_OSCILL_REVERSE_POS2[Z] DO
$AA_OVR[X]=0
; has exceeded the reversal point,
; the infeed axis is stopped.
; Activate oscillation
OS[Z]=1 FA[X]=1000 POS[X]=40 ; Deactivate oscillation
OS[Z]=0
M30
Extended Functions
Example 2
Oscillation with online change of the reversal position, i.e. any modification of reversal
position 1 via the user surface are immediately taken into account with active oscillation
movement.

$SA_OSCILL_REVERSE_POS1[Z]=-10
$SA_OSCILL_REVERSE_POS2[Z]=10
G0 X0 Z0
WAITP(Z)
ID=1 WHENEVER $AA_IM[Z] <
$$SA_OSCILL_REVERSE_POS1[Z] DO
$AA_OVR[X]=0
ID=2 WHENEVER $AA_IM[Z] >
$$SA_OSCILL_REVERSE_POS2[Z] DO
$AA_OVR[X]=0
; If the actual value of the oscillation axis
; has exceeded the reversal point,
; the infeed axis is stopped.
OS[Z]=1 FA[X]=1000 POS[X]=40 ; Activate oscillation
OS[Z]=0 ; Deactivate oscillation
M30
11.3.1 Infeed at reversal point 1 or 2
Function
As long as the oscillation axis has not reached the reversal point, the infeed axis does not
move.
Application
Direct infeed in reversal point
Programming
For reversal point 1:
WHENEVER $AA_IM[Z] <> $SA_OSCILL_REVERSE_POS1[Z]
DO $AA_OVR[X] = 0 $AA_OVR[Z] = 100
For reversal point 2:
DO $AA_OVR[X] = 0 $AA_OVR[Z] = 100
Extended Functions
Explanation of system variables:

$AA_IM[Z]: Current position of oscillating axis Z in the MCS
$SA_OSCILL_REVERSE_POS1[Z]: Position of the reversal point1 of the oscillation axis
$AA_OVR[X]: Axial override of the infeed axis
$AA_OVR[Z]: Axial override of the oscillation axis
Explanation of key words:
WHENEVER ... DO ... always when the condition is fulfilled, then ...
Infeed
The absolute infeed value is defined by the POSP instruction (see Section "Definition of
infeeds POSP (Page 663)").
Assignment
The assignment between the oscillation axis and the infeed axis is defined by the OSCILL
instruction (see Section "Assignment of oscillation and infeed axes OSCILL (Page 662)").
11.3.2 Infeed in reversal point range
Function
Reversal point range 1:
No infeed takes place provided the oscillation axis has not reached the reversal point range
(position at reversal point 1 plus contents of variables ii1). This applies on the condition that
reversal point 1 is set to a lower value than reversal point 2. If this is not the case, then the
condition must be changed accordingly.
Application
The purpose of the synchronized action is to prevent the infeed movement from starting until
the oscillation movement has reached reversal point range 1 (see "Figure 11-1 Arrangement
of oscillation and infeed axes plus terms (Page 654)").
Extended Functions
Programming
WHENEVER $AA_IM[Z] > $SA_OSCILL_REVERSE_POS1[Z] + ii1
DO $AA_OVR[X] = 0
$AA_IM[Z]: Current position of oscillating axis Z
$SA_OSCILL_REVERSE_POS1[Z]: Position of reversal point 1 of the oscillation axis
ii1: Size of the reversal point range (number of variables)
Function
The infeed axis stops until the current position (value) of the oscillation axis is lower than the
position at reversal point2 minus the contents of variable ii2. This applies on condition that
the setting for reversal point position 2 is higher than that for reversal point position 1. If this
is not the case, then the condition must be changed accordingly.
Application
The purpose of the synchronized action is to prevent the infeed movement from starting until
the oscillation movement has reached reversal point range 2 (see "Figure 11-1 Arrangement
of oscillation and infeed axes plus terms (Page 654)").
Programming
WHENEVER $AA_IM[Z] < $SA_OSCILL_REVERSE_POS2[Z] - ii2
DO $AA_OVR[X] = 0
Explanation:
$AA_IM[Z]: Current position of oscillating axis Z
$SA_OSCILL_REVERSE_POS2[Z]: Position of reversal point 2 of the oscillation axis
ii2: Magnitude of reversal range 2 (user variable)
Extended Functions
Infeed
The absolute infeed value is defined by the POSP instruction (see Section "Definition of
infeeds POSP (Page 663)").
Assignment
The assignment between the oscillation axis and the infeed axis is defined by the OSCILL
instruction (see Section "Assignment of oscillation and infeed axes OSCILL (Page 662)").
See also
Oscillation controlled by synchronized actions (Page 653)
11.3.3 Infeed at both reversal points
General procedure
The functions described above for infeed at the reversal point and in the reversal point range
can be freely combined.
Combinations
Infeed:
to U1 - to U2
to U1 - range U2
range U1 - to U2
range U1 - range U2
One-sided infeed
to U1
to U2
range U1
range U2
(See Section "Infeed at reversal point 1 or 2 (Page 656)" and "Infeed in reversal point range
(Page 657)")
Extended Functions
11.3.4 Stop oscillation movement at the reversal point
Function
Reversal point 1:
Every time the oscillation axis reaches reversal position 1, it must be stopped by means of
the override and the infeed movement started.
Application
The synchronized action is used to hold the oscillation axis stationary until partial infeed has
been executed. This synchronized action can be omitted if the oscillation axis need not wait
at reversal point 1 until partial infeed has been executed. At the same time, this
synchronized action can be used to start the infeed movement if this has been stopped by a
previous synchronized action which is still active.
Programming
WHENEVER $AA_IM[oscillation axis] == $SA_OSCILL_REVERSE_POS1[oscillation axis]
DO $AA_OVR[oscillation axis] = 0 $AA_OVR[infeed axis] = 100
$AA_IM[oscillation axis]: Current position of oscillation axis
$SA_OSCILL_REVERSE_POS1[oscillation axis]: Reversal point 1 of the oscillation axis
$AA_OVR[oscillation axis]: Axial override of the oscillation axis
$AA_OVR[infeed axis]: Axial override of the infeed axis
Function
Reversal point 2:
Every time the oscillation axis reaches reversal position 2, it must be stopped by means of
the override 0 and the infeed movement started.
Application
The synchronized action is used to hold the oscillation axis stationary until partial infeed has
been executed. This synchronized action can be omitted if the oscillation axis need not wait
at reversal point 2 until partial infeed has been executed. At the same time, this
synchronized action can be used to start the infeed movement if this has been stopped by a
previous synchronized action which is still active.
Extended Functions
Programming
WHENEVER $AA_IM[oscillation axis] == $SA_OSCILL_REVERSE_POS2[oscillation axis]
DO $AA_OVR[oscillation axis] = 0 $AA_OVR[infeed axis] = 100
Explanation:
$AA_OVR[oscillation axis]: Axial override of the oscillation axis
$AA_OVR[infeed axis]: Axial override of the infeed axis
11.3.5 Oscillation movement restarting
Function
The oscillation axis is started via the override whenever the distance-to-go for the currently
traversed path section of the infeed axis = 0, i.e. partial infeed has been executed.
Application
The purpose of this synchronized action is to continue the movement of the oscillation axis
on completion of the part infeed movement. If the oscillation axis need not wait for
completion of partial infeed, then the motion-synchronous action with which the oscillation
axis is stopped at the reversal point must be omitted.
Programming
WHENEVER $AA_DTEPW[infeed axis] == 0
DO $AA_OVR[oscillation axis] =100
$AA_DTEPW[infeed axis]: axial remaining travel distance for the infeed axis in the MCS:
Path distance of the infeed axis
$AA_OVR[oscillation axis]: Axial override for oscillation axis
Extended Functions
11.3.6 Do not start partial infeed too early
Function
The functions described above prevent any infeed movement outside the reversal point or
the reversal point range. On completion of an infeed movement, however, restart of the next
partial infeed must be prevented.
Application
A channel-specific flag is used for this purpose. This flag is set at the end of the partial infeed
(partial distance-to-go == 0) and is deleted when the axis leaves the reversal point range.
The next infeed movement is then prevented by a synchronized action.
Programming
WHENEVER $AA_DTEPW[infeed axis] == 0
DO $AC_MARKER[Index]=1
and, for instance, for reversal point 1:
DO $AC_MARKER[Index]=0
WHENEVER $AC_MARKER[index]==1
DO $AA_OVR[infeed axis]=0
$AA_DTEPW[infeed axis]: axial remaining travel distance for the infeed axis in the MCS:
Path distance of the infeed axis
$AC_MARKER[index]: Channel-specific marker with index
$AA_OVR[infeed axis]: Axial override for infeed axis
11.3.7 Assignment of oscillation and infeed axes OSCILL
Function
One or several infeed axes are assigned to the oscillation axis with command OSCILL.
Oscillation motion starts.
Extended Functions
The PLC is informed of which axes have been assigned via the NC/PLC interface. If the PLC
is controlling the oscillation axis, it must now also monitor the infeed axes and use the
signals for the infeed axes to generate the reactions on the oscillation axis via 2 stop bits of
the interface.
Application
The axes whose response has already been defined by synchronous conditions are
assigned to one another for activation of oscillation mode. The oscillation movement is
started.
Programming
OSCILL[oscillation axis] = (infeed axis1, infeed axis2, infeed axis3)
Infeed axis2 and infeed axis3 in brackets plus their delimiters can be omitted if they are not
required.
11.3.8 Definition of infeeds POSP
Function
The control receives the following data for the infeed axis:
Total infeed
Part infeed at reversal point/reversal point range
Part infeed response at end
Application
This instruction must be given after activation of oscillation with OSCILL to inform the
controller of the required infeed values at the reversal points/reversal point ranges.
Programming
POSP[infeed axis] = (end position, part section, mode)
End position: End position for the infeed axis after all partial infeeds have been traversed.
Part section: Part infeed at reversal point/reversal point range
Mode 0: For the last two part steps, the remaining path up to the target point is divided into
two equally large residual steps (default setting).
Mode 1: The part length is adjusted such that the total of all calculated part lengths
corresponds exactly to the path up to the target point.
Extended Functions
11.3.9 External oscillation reversal

For example, keys on the PLC can be used to change the oscillation area or instantaneously
reverse the direction of oscillation.
The edge-triggered PLC input signal DB31, ... DBX28.0 (oscillation reversal) is used to brake
the current oscillation motion and then traverse in the opposite direction. The braking phase
is signaled via the PLC output signal DB31, ... DBX100.2 (oscillation reversal active).
The braking position of the axis can be accepted as the new reversal position by means of
the PLC signal DB31, ... DBX28.4 (change reversal position).
The PLC input signal DB31, ... DBX28.3 (select reversal point) is ignored, but rather the
change affects the last initiated external oscillation reversal command.
No change in the reversal points applied via handwheel or JOG keys may be active for the
relevant axis. If handwheel or JOG key changes are currently active, display alarm 20081
(Braking position cannot be accepted as reversal position - handwheel active) will be
generated. The alarm is automatically reset when the conflict has been eliminated.
Hold time
No stop time is applied for a change of direction due to an external oscillation reversal. The
axis waits for the exact stop fine signal. Any configured exact stop condition is fulfilled.
Infeed motion
With non-modal oscillation, no infeed movement is performed for a change of direction due
to an external oscillation reversal as the reversal position has not been reached and
consequently the appropriate synchronized action is not fulfilled.
System variables
The braking position can be scanned via system variable $AA_OSCILL_BREAK_POS1,
when approach to reversal position 1 is aborted or via
$AA_OSCILL_BREAK_POS2 when approach to reversal position 2 is aborted.
If the relevant reversal point is approached again, the position of the reversal point can be
scanned in $AA_OSCILL_BREAK_POS1 or $AA_OSCILL_BREAK_POS2.
In other words, only after an External oscillation reversal command is there a difference
between the values in $AA_OSCILL_BREAK_POS1 and $AA_OSCILL_REVERSE_POS1 or
the values in $AA_OSCILL_BREAK_POS2 and $AA_OSCILL_REVERSE_POS2.
External oscillation reversal can therefore be detected by a synchronized action (see Section
"Examples (Page 665)").
Extended Functions
Special cases
If the PLC input signal "oscillation reversal" is activated as the axis is approaching the start
position, the approach movement is aborted and the axis continues by approach interruption
position 1.
If the PLC input signal "oscillation reversal" is set during a stop period, the stop timer is
deactivated; if exact stop fine has not yet been reached, the axis waits for the exact stop fine
reached signal before continuing its motion.
If the PLC input signal "oscillation reversal" is activated as the axis is approaching the end
position, the approach movement is aborted and oscillation is terminated.
For an example of the external oscillation reversal command (see Section "Change reversal
position via synchronized action with "external oscillation reversal" (Page 676)").
Availability of the "Oscillation" function

The function is an option ("oscillation functions"), which must be assigned to the hardware
through the license management.
11.5 Examples
Requirements
The examples given below require components of the NC language specified in the sections
entitled:
Asynchronous oscillation
and
Oscillation controlled by synchronized actions.
Extended Functions
11.5 Examples
11.5.1 Example of asynchronous oscillation
Task
The oscillation axis Z must oscillate between -10 and 10. Approach reversal point 1 with
exact stop coarse and reversal point 2 without exact stop. The oscillation axis feedrate must
be 5000. 3 sparking-out strokes must be executed at the end of the machining operation
followed by approach by oscillation axis to end position 30. The feedrate for the infeed axis is
1000, end of the infeed in X direction is at 15.
Program section

OSP1[Z]=-10 ; Reversal point 1
OSP2[Z]=10 ; Reversal point 2
OST1[Z]=-1 ; Stop time at reversal point 1: Exact stop coarse
OST2[Z]=-2 ; Stop time at reversal point 2: without exact stop
FA[Z]=5000 ; Infeed for oscillating axis
OSNSC[Z]=3 ; three spark-out strokes
OSE[Z]=-3 ; End position
OS1 F500 X15 ; start oscillation, infeed X axis
; with infeed 500, feed target 15
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Figure 11-2 Sequences of oscillation movements and infeed, example 1
Extended Functions
11.5 Examples
11.5.2 Example 1 of oscillation with synchronized actions
Task
Direct infeed must take place at reversal point 1; the oscillation axis must wait until the partial
infeed has been executed before it can continue traversal. At reversal point 2, the infeed
must take place at a distance of -6 from reversal point 2; the oscillation axis must not wait at
this reversal point until partial infeed has been executed. Axis Z is the oscillation axis and
axis X is the infeed axis (see Section "Oscillation controlled by synchronized actions
(Page 653)).
Note
The setting data OSCILL_REVERSE_POS_1/2 are values in the machine coordinate
system; therefore comparison is only suitable with $AA_IM[n].
Program section

; Example 1: Oscillation with synchronized actions
OSP1[Z]=10 OSP2[Z]=60 ; explain reversal points 1 and 2
OST1[Z]=-2 OST2[Z]=0 ; Reversal point 1: without exact stop
; Reversal point 2: Exact stop fine
FA[Z]=5000 FA[X]=250 ; Feed for oscillating axis, feedrate, infeed axis
OSCTRL[Z]=(1+8+16,0) ; Switch off oscillation motion at reversal point 1
; After delete DTG spark-out and approach end position
; After DTG, approach relevant reversal position
;
OSNSC[Z]=3 ; 3 sparking-out strokes
OSE[Z]=0 ; End position = 0
WAITP(Z) ; enable oscillation for the Z axis
;
; motion-synchronous actions:
;
; always, when the current position of the oscillating axis in the
; Machine Coordinate System
; not equal to reversal position 1
; then set the marker with index 1 to value 0
; (Reset marker 1)
WHENEVER $AA_IM[Z]<>$SA_OSCILL_REVERSE_POS1[Z] DO $AC_MARKER[1]=0
;
Extended Functions
11.5 Examples

; less than the beginning of reversal range 2
; (here: reversal point 2 -6),
; then set the axial override of the infeed axis to 0%.
; and set the marker with index 2 to value 0
; (Reset marker 2)
WHENEVER $AA_IM[Z]<$SA_OSCILL_REVERSE_POS2[Z]-6 DO $AA_OVR[X]=0 $AC_MARKER[2]=0
;
; equal to reversal position 1,
; then set the axial override of the oscillation axis to 0%
;
; and Set the axial override of the infeed axis to
; 100% (so that the previous synchronized action
; is cancelled!)
WHENEVER $AA_IM[Z]==$SA_OSCILL_REVERSE_POS1[Z] DO $AA_OVR[Z]=0 $AA_OVR[X]=100
;
; always, when the distance-to-go of the partial infeed is
; equal to 0,
WHENEVER $AA_DTEPW[X]==0 DO $AC_MARKER[2]=1 $AC_MARKER[1]=1
;
; always, when the flag with index 2 is
; equal to 1,
; then Set the axial override of the infeed axis to
; 0%, this prevents a premature infeed
; (oscillation axis has not exited the
; reversal point 1).
;
WHENEVER $AC_MARKER[2]==1 DO $AA_OVR[X]=0
;
; equal to 1,
; 0%, this prevents a premature infeed
; (oscillation axis has not exited the
; reversal point range 2).
; 100% ('Start' oscillation)
WHENEVER $AC_MARKER[1]==1 DO $AA_OVR[X]=0 $AA_OVR[Z]=100
;
Extended Functions
11.5 Examples

; if the current position of the oscillating axis in the MCS is
; equal to reversal position 1,
; 100%
; 0% (so that the second synchronized action
; is cancelled once!)
WHEN $AA_IM[Z]==$SA_OSCILL_REVERSE_POS1[Z] DO $AA_OVR[Z]=100 $AA_OVR[X]=0
;
;------------------------------------------
OSCILL[Z]=(X) ; Assign axis X to the oscillation axis Z as
POSP[X]=(5,1,1)
; infeed axis, this should
; infeed to end position 5 in steps
; from 1 and the sum of all part lengths should
; give exactly the end position
M30 ; End of program
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Extended Functions
11.5 Examples
11.5.3 Example 2 of oscillation with synchronized actions
Task
No infeed must take place at reversal point 1. At reversal point 2, the infeed must take place
at distance ii2 from reversal point 2; the oscillation axis must wait at this reversal point until
partial infeed has been executed. Axis Z is the oscillation axis and axis X the infeed axis.
Program section
Example 2: Oscillation with synchronized actions

DEF INT ii2 ; Define variable for reversal area 2
;
OST1[Z]=0 OST2[Z]=0 ; Reversal point 1: Exact stop fine
FA[Z]=5000 FA[X]=100 ; Feed for oscillating axis, feed for infeed axis
; After delete distance-to-go, spark-out and end position
; Approach appropriately after delete distance-to-go
; Approach reversal position
ii2=2 ; Set reversal point range
WAITP(Z) ; permit oscillation for Z axis
;
; less than the start of reversal area 2
; then set the axial override of the feed axis
; to 0%
WHENEVER $AA_IM[Z]<$SA_OSCILL_REVERSE_POS2[Z]-ii2 DO $AA_OVR[X]=0 $AC_MARKER[0]=0
;
; greater or equal to reversal position 2
; then set the axial override of the oscillating axis
; to 0%
WHENEVER $AA_IM[Z]>=$SA_OSCILL_REVERSE_POS2[Z] DO $AA_OVR[Z]=0
;
Extended Functions
11.5 Examples

; always, when the distance-to-go of the partial infeed is
; equal to 0,
WHENEVER $AA_DTEPW[X] == 0 DO $AC_MARKER[0]=1
;
; equal to 1,
; then set the axial override of the infeed axis to 0%
; to prevent a new premature infeed
; (oscillation axis has not yet exited the reversal point
range 2,
; but the infeed axis is ready for a
; new infeed)
; and set the axial override of the oscillation axis to 100%
; (this cancels the 2nd synchronized action)
;
;
OSCILL[Z]=(X) ; Start the axes
POSP[X]=(5,1,1)
; The oscillating axis Z is assigned axis X as
; an infeed axis
; Axis X should travel to end position 5 in
; increments of 1
;
M30
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Extended Functions
11.5 Examples
11.5.4 Examples for starting position
11.5.4.1 Define starting position via language command

OST1[Z]=-2 OST2[Z]=0 ; Reversal point 1: without exact stop
FA[Z]=5000 FA[X]=2000 ; Infeed for oscillating axis,
; feedrate for infeed axis
; after delete DTG spark-out and approach end position,
; After DTG, approach relevant reversal position
;
OSB[Z]=0 ; Start position = 0
OS[Z]=1 X15 F500 ; Start oscillation, continuous infeed
WAITP(Z) ; wait for completion of the oscillation motion
M30
Explanation
When the Z axis starts oscillation, it first approaches the starting position (position = 0 in the
example) and then begins the oscillation motion between the reversal points 10 and 60.
When the X axis has reached its end position 15, the oscillation finishes with 3 sparking out
strokes and approach of end position 0.
11.5.4.2 Start oscillation via setting data

WAITP(Z)
STOPRE
$SA_OSCILL_REVERSE_POS1[Z]=-10 ; reversal position 1 = -10
$SA_OSCILL_REVERSE_POS2[Z]=30 ; reversal position 2 = 30
$SA_OSCILL_START_POS[Z] = -50 ; Start position = -50
$SA_OSCILL_CTRL_MASK[Z] = 512 ; Approach start position,
; on switch-off, stop at the next
; reversal point
; do not approach any end position
; no sparking-out strokes for DTG
Extended Functions
11.5 Examples

$SA_OSCILL_VELO[ Z ] = 5000 ; Infeed for oscillating axis
$SA_OSCILL_IS_ACTIVE[ Z ] = 1 ; starting
$SA_OSCILL_DWELL_TIME1[ Z ] = -2 ; without wait for exact stop
$SA_OSCILL_DWELL_TIME2[ Z ] = 0 ; wait for fine exact stop
STOPRE
X30 F100
$SA_OSCILL_IS_ACTIVE[ Z ] = 0 ; Stop
WAITP(Z)
M30
Description
When the Z axis starts oscillation, it first approaches the starting position (position = -50 in
the example) and then begins the oscillation motion between the reversal points -10 and 30.
When the X axis has reached its end position 30, the oscillation finishes at the next
approached reversal point.
11.5.4.3 Non-modal oscillation (starting position = reversal point 1)
Oscillation with synchronized actions

N701 ; Oscillation with synchronized actions,
; start position == reversal point 1
;
N702 OSP1[Z]=10 OSP2[Z]=60 ; explain reversal points 1 and 2
N703 OST1[Z]=0 OST2[Z]=0 ; Reversal point 1: Exact stop coarse
N704 FA[Z]=5000 FA[X]=2000 ; Infeed for oscillating axis,
; feedrate for infeed axis
N705 OSCTRL[Z]=(1+8+16.0) ; switch off oscillation motion at
; reversal point 1 after DTG spark-out
; and approach end position
; After DTG, approach relevant
; reversal position
;
N706 OSNSC[Z]=3 ; 3 sparking-out strokes
N707 OSE[Z]=0 ; End position = 0
N708 OSB[Z]=10 ; Start position = 10
N709 WAITP(Z) ; enable oscillation for the Z axis
;
Extended Functions
11.5 Examples

; set marker with index 2 on 1 (initialization)
WHEN TRUE DO $AC_MARKER[2]=1
;
; always, when the marker with index 2 equals 0
; and the current position of the oscillating
axis
; does not equal the reversal position 1
; then set the marker with index 1 to 0.
;
WHENEVER ($AC_MARKER[2] == 0) AND $AA_IW[Z]>$SA_OSCILL_REVERSE_POS1[Z])
DO $AC_MARKER[1]=0
; always, when the current position of the oscillating axis
; is less than the start of reversal range 2

;
; to 0 and set the marker with index 0 to
; 0
WHENEVER $AA_IW[Z]<$SA_OSCILL_REVERSE_POS2[Z]-6 DO $AA_OVR[X]=0 $AC_MARKER[0]=0
;
; always, when the current position of the oscillating axis
; is equal to the reversal position 1,
; then set the axial override of the oscillating axis
; to 0 and set the axial override of the
; infeed axis to 100% (so that the
; previous synchronized action is cancelled!)
WHENEVER $AA_IW[Z]==$SA_OSCILL_REVERSE_POS1[Z] DO $AA_OVR[Z]=0 $AA_OVR[X]=100
;
; always, when the distance-to-go of the partial infeed equals
0
;
; then Set the marker with index 0 to 1 and
; set the marker with index 1 to 1 and
WHENEVER $AA_DTEPW[X]==0 DO $AC_MARKER[0]=1 $AC_MARKER[1]=1
;
; always, when the marker with index 0 equals 1,
; to 0 to prevent a new premature
; infeed!
WHENEVER $AC_MARKER[0]==1 DO $AA_OVR[X]=0
;
Extended Functions
11.5 Examples

; always, when the marker with index 1 equals 1,
; to 0 (to prevent a new premature
; infeed!) and set the
; axial override of the oscillation axis to 100%
; (so that the previous
; synchronized action is canceled!)
;
; When the current position of the oscillating axis
; is equal to the reversal position 1,
; then reset the marker with index 2,
; release the first synchronized action (no
; infeed when reaching the start position
; == reversal position 1)
WHEN $AA_IW[Z]==$SA_OSCILL_REVERSE_POS1[Z] DO $AC_MARKER[2]=0
;
;----------------------------------
N750 OSCILL[Z]=(X) POSP[X]=(5,1,1)
; Assign axis X to the oscillation axis Z as infeed axis,
; this should infeed to end position 5
; in substeps of 1 and the sum of all sublengths
; should be exactly the same as the end position.
;
N780 WAITP(Z) ; release the Z axis
;
N790 X0 Z0
N799 M30 ; End of program
Description
The starting position matches reversal point 1. The WHEN .... synchronized actions (see
above) prevent an infeed when the starting position is reached.
Extended Functions
11.6 Data lists
11.5.5 Example of external oscillation reversal
11.5.5.1 Change reversal position via synchronized action with "external oscillation reversal"

DEFINE BREAKPZ AS $AA_OSCILL_BREAK_POS1[Z]
DEFINE REVPZ AS $SA_OSCILL_REVERSE_POS1[Z]

OSB[Z]=0 ; Start position = 0
; At external reversal of oscillation for

; oscillation reversal point 1, adapt this
WHENEVER BREAKPZ <> REVPZ DO $$SA_OSCILL_REVERSE_POS1 = BREAKPZ
OS[Z]=1 X150 F500 ; Start oscillation, continuous infeed
WAITP(Z) ; wait for completion of the oscillation motion
M30
11.6 Data lists
11.6.1 Machine data

10710 PROG_SD_RESET_SAVE_TAB Oscillations to be saved from SD
11460 OSCILL_MODE_MASK Control screen form for asynchronous oscillation
Extended Functions
11.6 Data lists
11.6.2 Setting data

43700 OSCILL_REVERSE_POS1 Position at reversal point 1
43710 OSCILL_REVERSE_POS2 Position at reversal point 2
43720 OSCILL_DWELL_TIME1 Stop time at reversal point 1
43730 OSCILL_DWELL_TIME2 Stop time at reversal point 2
43740 OSCILL_VELO Feed velocity of oscillation axis
43750 OSCILL_NUM_SPARK_CYCLES Number of sparking-out strokes
43760 OSCILL_END_POS Position after sparking-out strokes/at end of oscillation
movement
43770 OSCILL_CTRL_MASK Control screen form for oscillation
43780 OSCILL_IS_ACTIVE Oscillation movement ON/OFF
43790 OSCILL_START_POS Position that is approached after oscillation before reversal
point 1, if activated in SD43770:
11.6.3 Signals

External oscillation reversal DB31, ... .DBX28.0 -
Set reversal point DB31, ... .DBX28.3 -
Alter reversal point DB31, ... .DBX28.4 -
Stop at next reversal point DB31, ... .DBX28.5 -
Stop along braking ramp DB31, ... .DBX28.6 -

Oscillation reversal is active DB31, ... .DBX100.2 -
Oscillation cannot start DB31, ... .DBX100.3 -
Error during oscillation movement DB31, ... .DBX100.4 -
Sparking-out active DB31, ... .DBX100.5 -
Extended Functions
11.6 Data lists

Oscillation movement active DB31, ... .DBX100.6 -
Oscillation active DB31, ... .DBX100.7 -
11.6.4.1 Main run variables for motion-synchronous actions
Main run variable_read

The following variables are provided for main run variable_read:
$A_IN[<arith. expression>] digital input (Boolean)

$A_OUT[<arith. expression>] digital output (Boolean)
$A_INA[<arith. expression>] analog input (Boolean)
$A_OUTA[<arith. expression>] analog output (Boolean)
$A_INCO[<arith. expression>] comparator inputs (Boolean)
$AA_IW[<axial expression>] actual position PCS axis (real)
$AA_IB[<axial expression>] actual position BCS axis (real)
$AA_IM[<axial expression>] Actual position MCS axis (IPO setpoints) (real)
With $AA_IM[S1] setpoints for spindles can be
evaluated. Modulo calculation is used for spindles
and rotary axes, depending on machine data
$MA_ROT_IS_MODULO and
$MA_DISPLAY_IS_MODULO.
$AA_OSCILL_BREAK_POS1 Breaking position after external oscillation reversal
when approaching reversal point 1
$AA_OSCILL_BREAK_POS2 Breaking position after external oscillation reversal
when approaching reversal point 2
$AC_TIME Time from the start of the block (real) in seconds
(including the times for the internally generated
intermediate blocks)
$AC_TIMES Time from the start of the block (real) in seconds
(without times for the internally generated
$AC_TIMEC Time from the start of the block (real) in IPO steps
(including steps for the internally generated
$AC_TIMESC Time from the start of the block (real) in IPO steps
(without steps for the internally generated
$AC_DTBB Distance from beginning of block in BCS
(Distance to begin, baseCoor) (real)
Extended Functions
11.6 Data lists
$AC_DTBW Distance from beginning of block in PCS

(Distance to begin, workpieceCoor) (real)
$AA_DTBB[<axial expression>] axial distance from beginning of block in BCS
(Distance to begin, baseCoor) (real)
$AA_DTBW[<axial expression>] axial distance from beginning of block in PCS
(Distance to begin, workpieceCoor) (real)
$AC_DTEB Distance to end of block in BCS (Distance to end)
(Distance to end, baseCoor) (real)
$AC_DTEW Distance to end of block in PCS
(Distance to end, workpieceCoor) (real)
$AA_DTEB[<axial expression>] axial distance to end of movement in BCS
(Distance to end, baseCoor) (real)
$AA_DTEW[<axial expression>] axial distance to end of movement in PCS
(Distance to end, workpieceCoor) (real)
$AC_PLTBB Distance from beginning of block in BCS
(Path Length from begin, baseCoor) (real)
$AC_PLTEB Distance to end of block in BCS (Distance to end)
(Path Length to end, baseCoor) (real)
$AC_VACTB Path speed in BCS
(Velocity actual, baseCoor) (real)
$AC_VACTW Path speed in PCS
(Velocity actual, workPieceCoor) (real)
$AA_VACTB[<axial expression>] Axis velocity in BCS
(Velocity actual, baseCoor) (real)
$AA_VACTW[<axial expression>] Axis velocity in PCS
(Velocity actual, workPieceCoor) (real)
$AA_DTEPB[<axial expression>] axial distance-to-go for oscillation infeed in BCS
(Distance to end, pendulum, baseCoor) (real)
$AA_DTEPW[<axial expression>] axial distance-to-go for oscillation infeed in PCS
(Distance to end, pendulum, workpieceCoor) (real)
$AC_DTEPB Path distance-to-go for oscillation infeed in BCS
(not P2) (Distance to end, pendulum, baseCoor)
(real)
$AC_DTEPW Path distance-to-go for oscillation infeed in PCS
(not P2) (Distance to end, pendulum,
workpieceCoor) (real)
$AC_PATHN (Path parameter normalized) (real)
Normalized path parameter: 0 for beginning of
block to 1 for end of block
$AA_LOAD[<axial expression>] Drive utilization
$AA_POWER[<axial expression>] Drive efficiency in W
$AA_TORQUE[<axial expression>] Drive torque setpoint in Nm
$AA_CURR[<axial expression>] Actual current value of axis
Extended Functions
11.6 Data lists
$AC_MARKER[<arithmetic_expression>] (int) Flag variables: can be used to build complex

conditions in synchronous actions:
8 Markers (Index 0 - 7) are available.
Reset sets the markers to 0.
Example:
WHEN .....DO $AC_MARKER[0]=2
WHEN .....DO $AC_MARKER[0]=3
WHEN $AC_MARKER[0]==3 DO $AC_OVR=50
Can be read and written independently of
synchronous actions in the parts program:
IF $AC_MARKER == 4 GOTOF SPRUNG
$AC_PARAM[<arithmetic_expression>] (real) Floating-decimal parameter for synchronous
actions. Serves as intermediate saving and
evaluation in synchronous actions.
50 Parameters (Index 0 - 49) are available.
$AA_OSCILL_REVERSE_POS1
[<axial expression>] (real)
$AA_OSCILL_REVERSE_POS2 current oscillation reversal points 1 and 2:
[<axial expression>] (real) The current setting data from
$SA_OSCILL_REVERSE_POS1 or
$SA_OSCILL_REVERSE_POS2 is read.
This enables setting data changes at the reversal
positions during active oscillation, i.e. during an
active synchronous action.
Conditions
Conditions for motion-synchronous actions are formulated:
Main run variable comparison operator expression
For details see:
References:
Function Manual Synchronized Actions
Extended Functions
R2: Rotary axes 12
Rotary axes in machine tools

Rotary axes are used on many modern machine tools. They are required for tool and
workpiece orientation, auxiliary movements and various other technological or kinematic
purposes.
Typical examples for the use of rotary axes are the 5-axis milling machines. Only with the aid
of rotary axes can the tip of the tool be positioned at any point on the workpiece for this type
of machine.
Depending on the type of machine, many different demands are placed on a rotary axis. In
order that the control can be adapted to the various types of machine, the individual rotary
axis functions can be activated by means of machine data or special programming.
Rotary axes are always programmed in degrees. They are generally characterized by the
fact that they assume the same position after exactly one rotation (modulo 360 degrees).
Depending on the application in question, the traversing range of the rotary axis can be
limited to less than 360 degrees (e.g., on swiveling axes for tool holders) or may be unlimited
(e.g., when the tool or workpiece is rotated).
In many ways, the responses and features of rotary axes are identical to those of linear
axes. The following description of functions is limited to a description of the special features
of rotary axes and how they differ from linear axes.
Definition of a rotary axis

An axis can be declared as a rotary axis using the following axis-specific machine data:
MD30300 $MA_IS_ROT_AX
Geometry axes are defined as linear axes. Any attempt to define them as rotary axes will be
rejected with alarm 4200 (Geometry axis cannot be defined as rotary axis).
Only when an axis has been declared as a rotary axis can it perform or use the functions
described on the following pages (e.g., unlimited traversing range, modulo display of axis
position, etc.).
Several axes can be declared as rotary axes simultaneously.
Types of rotary axis

Depending on the application, the operating range of a rotary axis can be unlimited
(endlessly rotating in both directions [MD30310 $MA_ROT_IS_MODULE = 1]), limited by a
software limit switch (e.g., operating range between 0 and 60) or limited to an appropriate
number of rotations (e.g., 1000).
Some typical rotary-axis applications are listed below.
Extended Functions
R2: Rotary axes
Typical applications
5-axis machining (operating range limited or unlimited)
Rotary axis for eccentric machining (unlimited operating range)
Rotary axis for cylindrical or form grinding (unlimited operating range)
C axis with TRANSMIT (unlimited operating range)
Rotary axis on winding machines (unlimited operating range)
Rotary workpiece axis (C) on hobbing machines (unlimited operating range)
Round tool magazines and tool turrets (unlimited operating range)
Rotary axis for peripheral surface transformation (limited operating range)
Swivel axes for gripping (operating range 360)
Rotary axes for swiveling (operating range < 360; e.g., 60)
Milling swivel axis (A) on hobbing machines (operating range, e.g., 90)
Axis addresses
Coordinate axes and directions of movement of numerically-controlled machine tools are
designated according to DIN.
DIN 66025 specifies the following axis addresses for rotary or swivel axes:
A, B and C with X, Y and Z as middle axis
This means that A rotates about X, B rotates about Y and C rotates about Z (see fig.).
The positive rotary-axis direction of rotation corresponds to a clockwise rotation when
looking in the positive axis direction of the corresponding middle axis (see fig.).
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Figure 12-1 Axis identifiers and directions of movement for rotary axes
Extended Functions
R2: Rotary axes
Extended addressing (e.g., C2=) or freely configured axis addresses can be used for
additional rotary axes.
Note
Machine data MD20050 $MC_AXCONF_GEOAX_ASSIGN_TAB (assignment of geometry
axis to channel axis) must be adapted to suit the corresponding axis.
Units of measurement
The following units of measurement apply as standard to inputs and outputs for rotary axes:
Units of measurement for rotary axes

Physical quantity Unit
Angular position Degrees
Programmed angular velocity Degrees/min
MD for angular velocity 1) rev/min
MD for angular acceleration 1) rev/sec2
MD for angular jerk limitation 1) rev/sec3
1) In the case of axis-specific machine data, these units are interpreted by the control as
soon as the axis is declared as a rotary axis. The user can define other units for data
inputs/outputs using machine data.
References:
Function Manual Basic Functions; Velocities, Setpoint/Actual Value Systems, Closed-Loop
Control (G2)
Operating range
The operating range can be defined by means of axis-specific machine and setting data
(software limit switches and working-area limitations). As soon as modulo conversion is
activated for the rotary axis (MD30310 $MA ROT_IS_MODULO = 1), the operating range is
set to unlimited and the software limit switches and working-area limitations become inactive.
Using the following interface signal, software limit switches/working-area limitations can also
be dynamically activated for modulo rotary axes by the PLC (where relevant, initiated from
the part program using M/H functions):
DB31, ... DBX12.4 (modulo-limit enabled)
The feedback signal of the NC is realized using the interface signal:
DB31, ... DBX74.4 (modulo-limit enabled active)
Extended Functions
R2: Rotary axes
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Figure 12-2 Limited operating area of a modulo rotary axis
Position display
The value range for the position display can be set to the modulo 360 representation, which
is frequently selected for rotary axes:
MD30320 $MA_DISPLAY_IS_MODULO = 1
Feedrate
The programmed feedrate F corresponds to an angular velocity (degrees/min) in the case of
rotary axes.
If rotary axes and linear axes traverse a common path with G94 or G95, the feedrate should be
interpreted in the linear-axis unit of measurement (e.g., mm/min, inch/min).
The tangential velocity of the rotary axis refers to diameter Dunit (unit diameter Dunit=360/).
In the case of unit diameter D=Dunit, the programmed angular velocity in degrees/min and the
tangential velocity in mm/min (or inch/min) are numerically identical.
In general, the following applies for tangential velocity:
F = Fangle * D/Dunit F = Tangential velocity [mm/min]

Fangle = Angular velocity [degrees/min]
D = Diameter acted on by F [mm]
With Dunit = 360/ Dunit= Unit diameter [mm]

= Circle constant Pi
Extended Functions
R2: Rotary axes
12.2 Modulo 360 degrees
In the JOG mode, the response of the axis/spindle also depends on the setting data:
SD41100 $SN_JOG_REV_IS_ACTIVE (revolutional feed rate for JOG active)
SD41100 $SN_JOG_REV_IS_ACTIVE
Active An axis/spindle is always traversed with revolutional feedrate:
MD32050 $MA_JOG_REV_VELO (revolutional feedrate for JOG)
or
MD32040 $MA_JOG_REV_VELO_RAPID (revolutional feedrate for JOG with rapid
traverse override)
, depending on the master spindle.
Not active The behavior of the axis/spindle depends on the setting data:
SD43300 $SA_ASSIGN_FEED_PER_REV_SOURCE (revolutional feedrate for
positioning axes/spindles)
Behavior of a geometry axis on which a frame with rotation acts, depends on the
channel-specific setting data:
SD42600 $SC_JOG_FEED_PER_REV_SOURCE (in the JOG mode revolutional
feed rate for geometry axes, on which the frame with rotation acts)
Term "modulo 360"

Rotary axes are frequently programmed in the 360 representation mode. The axis must be
defined as a rotary axis in order to use the modulo feature.
With respect to a rotary axis, the term "modulo" refers to the mapping of the axis position
within the control in the range 0 to 359.999. With path defaults > 360 (e.g., for incremental
programming using G91), the position is mapped in the range of values 0 to 360 following
conversion within the control. Mapping is performed in JOG and AUTOMATIC modes.
Exception: service display.
In the figure below, the rotary-axis absolute position in the positive direction of rotation is
represented as a spiral. An arrow marks the actual absolute position on this spiral (example:
point C' = 420). By tracing the arrow back around the circle (position 0 of the spiral and
circle are identical), it is possible to assign an appropriate modulo position within the 360
range to every absolute position. In the example below, absolute position point C' = 420 is
mapped onto point C = 60 using modulo conversion.
Extended Functions
R2: Rotary axes
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Figure 12-3 Modulo 360 map
Machine-data settings
Machine data can be used to define programming and positioning (MD30310
$MA_ROT_IS_MODULO) as well as the position display (MD30320
$MA_DISPLAY_IS_MODULO) individually in modulo 360 for each rotary axis, depending on
the particular machine requirements.
Axis is modulo
MD30310 $MA_ROT_IS_MODULO = 1:
Activation of this machine data allows the special rotary-axis response to be utilized. The
rotary-axis positioning response is thus defined during programming (G90, AC, ACP, ACN or DC).
A modulo 360 representation is executed within the control after the current zero offsets
have been taken into account. The resulting target position within a revolution is then
approached.
The software limit switches and working-area limitations are inactive, meaning that the
operating range is unlimited (continuously-turning rotary axis).
Extended Functions
R2: Rotary axes
Modulo position display
MD30320 $MA_DISPLAY_IS_MODULO
=1 For rotary axes, a position display with "modulo 360"(one revolution) is often required, i.e.,
with a positive direction of rotation the display is periodically reset within the control to 0.000
after 359.999 is reached, with a negative direction of rotation the positions are also
displayed in the range 0 to 359.999.
=0 Absolute-position display would, in the case of a positive direction of rotation, for example,
result in +360 being displayed after one revolution, +720 after two revolutions, etc, in
contrast to the modulo 360 display. In this case, the display range is limited by the control in
accordance with the linear axes.
Note
The modulo 360 position display should always be selected for a modulo axis (MD30310
$MA_ROT_IS_MODULO = 1).
Starting position for the modulo rotary axis

A start position not equal to 0 for the modulo range can be defined:
MD30340 $MA_MODULO_RANGE_START (start position of the modulo range)
For example, this means that a modulo range of -180 to +180 can be achieved by entering
-180 in MD30340.
The default setting of 0 (degrees) defines a modulo range of 0 - 360.
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Figure 12-4 Starting position of -180 changes the modulo range to -180 to + 180
Extended Functions
R2: Rotary axes
12.3 Programming rotary axes
Application
By approximating the two following machine data, indexing positions of modulo indexing
axes can be implemented in the same way as for the modulo range (see also Section "T1:
Indexing axes (Page 771)").
MD30503 $MA_INDEX_AX_OFFSET
MD30340 $MA_MODULO_RANGE_START
Note
General information about programming, see:
References:
Programming Manual Fundamentals
MD30310
Axis-specific machine data
MD30310 ROT_IS_MODULO (modulo conversion for rotary axis)
is used to define whether the rotary axis behaves as a linear axis during programming and
positioning or whether rotary-axis special features are taken into account.
These features and any differences (mainly with respect to absolute programming) are
explained on the following pages.
12.3.2 Rotary axis with active modulo conversion (continuously-turning rotary axis).
Activate modulo conversion

Set MD30310 $MA_ROT_IS_MODULO = 1.
Note
With modulo axes, it is advisable to set the position display to modulo 360 (set MD30320
$MA_DISPLAY_IS_MODULO = 1).
Extended Functions
R2: Rotary axes
Absolute programming (AC, ACP, ACN, G90)

Example for positioning axis: POS[axis name] = ACP(value)
The value identifies the rotary-axis target position in a range from 0 to 359.999.
Negative values are also possible if a range offset has been realized with the following
machine data:
MD30340 $MA_ MODULO_RANGE_START
MD30330 MA_MODULO_RANGE
ACP (positive) and ACN (negative) unambiguously define the rotary-axis traversing direction
(irrespective of the actual position).
When programming AC exclusively or with G90, the traversing direction depends on the
rotary-axis actual position. If the target position is greater than the actual position, the
axis traverses in the positive direction, otherwise it traverses in the negative direction.
The positioning behavior can be configured via:
MD30455 $MA_MISC_FUNCTION_MASK bit 2
Bit 2 = 0: with G90, modulo axis positioned as standard using AC
Bit 2 = 1: with G90, modulo axis positioned as standard using DC (shortest path)
Use of ACP and ACN: With asymmetrical workpieces, it must be possible to define the
traversing direction in order to prevent collisions during rotation.
Example:
C starting position is 0 (see figure below).
POS[C] = ACP(100) Rotary axis C traverses to position 100 in the positive direction of
rotation
POS[C] = ACN(300) C traverses to position 300 in the negative direction of rotation
POS[C] = ACP(240) C traverses to position 240 in the positive direction of rotation
POS[C] = AC (0) C traverses to position 0 in the negative direction of rotation
Extended Functions
R2: Rotary axes
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Figure 12-5 Examples of absolute programming for modulo axes
Absolute programming along the shortest path (DC)

POS[axis name] = DC(value)
The value identifies the rotary-axis target position in a range from 0 to 359.999. Alarm
16830, "Incorrect modulo position programmed", is output for values with a negative sign
or 360.
With DC (Direct Control), the rotary axis approaches the programmed absolute position
within one revolution along the shortest path (traversing movement max. 180).
The control calculates the direction of rotation and the traverse path according to the
current actual position. If the path to be traversed is the same in both directions (180),
the positive direction of rotation receives preference.
DC application example: the rotary table is required to approach the changeover position
in the shortest time (and, therefore, via the shortest path) possible.
If DC is programmed with a linear axis, alarm 16800, "DC traverse instruction cannot be
used", is output.
Extended Functions
R2: Rotary axes
Example:
C starting position is 0 (see figure below).
POS[C] = DC(100) C axis traverses to position 100 along the shortest path
POS[C] = DC(60) C axis traverses to position 60 along the shortest path.

Since, in this case, the path is equal to 180 in both
directions, preference is given to the positive direction of
rotation.
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Figure 12-6 Examples of DC programming
Block-search response
After a block search with calculation, the collected search position of the modulo conversion
can be interrogated using the $AC_RETPOINT system variable.
This system variable returns the position converted to modulo.
Supplementary conditions for ASUB after block search with calculation:
In this instance, as well as with the cross-channel block-search tool SERUPRO, the modulo
conversion simulated in the block search must be performed in the part program.
Extended Functions
R2: Rotary axes
Modulo rotary axis with/without working-area limitation

By setting the following interface signal for a modulo rotary axis, the working area
limitation/software limit switch can be dynamically switched on/switched off by the PLC
(similar to rotary axes):
DB31, ... DBX12.4
The actual state of the traversing range limitation is signaled back by the NC using the
following interface signal:
DB31, ... DBX74.4
The monitoring function is activated if interface signal DB31, ... DBX12.4 was set by the
PLC.
The M/H command, which causes the PLC to set the interface signal, must be followed by a
STOPRE to ensure through synchronization that only the blocks after the changeover are
monitored.
Supplementary conditions:
It is only possible to activate/deactivate software-limit-switch monitoring via the PLC interface
for modulo axes.
Traversing-range monitoring for modulo axes can be implemented only if the axis is
referenced and one limiting pair is active.
This always applies in the case of software limit switches, since these are always
activated/deactivated in pairs. To monitor working area limitations correctly, both limitations
must have been activated, either via G26/G25 or the setting data:
SD43400 $SA_ WORKAREA_PLUS_ENABLE
and
SD43410 $SA_WORKAREA_MINUS_ENABLE.
Example of a traversing-range-limitation switchover

A pallet with several clamped workpieces should be machined successively on a modulo
rotary axis. This pallet is then replaced by one with a built-on axis whose operating range
must be monitored to prevent damage to supply lines.
Configuration:
MD30300 $MA_IS_ROT_AX[AX4] = 1
MD30310 $MA_ROT_IS_MODULO[AX4] = 1
MD36110 $MA_POS_LIMIT_PLUS[AX4] = 340
MD36100 $MA_POS_LIMIT_MINUS[AX4] = 350
Extended Functions
R2: Rotary axes
Extract from part program:

M123 ; Insert the pallet with quadruple
clamping into the machine
Deactivate the software limit
switches on the B axis from the
PLC
DB35, DBX12.4=0
STOPRE ; Trigger a preprocessing stop
S1000 M3
G4 F2
G1 X0 Y300 Z500 B0 F5000
CYCLE84(500,400,0,350,0,1,4,10,,0,500,1000) ; drilling cycle
Z500
B90
Z500
B180
Z500
B270
Z500
G0 Z540 B0
M124 ; Insert the pallet with built-on
axis into the machine
Activate the software limit
switches on the B axis from the
PLC
DB35, DBX12.4=1
;
STOPRE ; Trigger a preprocessing stop
B270
Extended Functions
R2: Rotary axes
Incremental programming (IC, G91)

Example for positioning axis: POS[axis name] = IC(+/-value)
The value identifies the rotary-axis traversing distance. The value can be negative and
+/-360.
The value's sign unequivocally defines the rotary-axis traversing direction.
Application example: milling a spiral groove across several revolutions
Example:
Programming Effect
POS[C]=IC(720) C axis traverses to 720 incrementally in the positive direction
(two revolutions)
POS[C]=IC(-180) C axis traverses to 180 incrementally in the negative direction
Endless traversing range

As soon as the modulo function is active, no limit is placed on the traversing range (software
limit switches are not active). The rotary axis can now be programmed to traverse
continuously.
Example:
Program code
LOOP:
POS[C] = IC(720)
GOTOB LOOP
12.3.3 Rotary axis without modulo conversion
Deactivate modulo conversion

Set MD30310 $MA_ROT_IS_MODULO = 0.
Absolute programming (AC, G90)

Example for positioning axis: POS[axis name] = AC (+/-value)
The value and its sign uniquely identify the rotary-axis target position. The value can be
+/-360. The position value is limited by the software-limit-switch positions.
The traversing direction is ascertained by the control according to the signed rotary-axis
actual position.
If ACP or ACN is programmed, alarm 16810, "ACP traverse instruction cannot be used", or
alarm 16820 "ACN traverse instruction cannot be used", is output.
Application example:
Linear movements (cam gear) are linked to the rotary axis, thus certain end positions
may not be overtraveled.
Extended Functions
R2: Rotary axes
Example:
Programming Effect
POS[C] = AC (-100) Rotary axis C traverses to position -100;
traversing direction depends on the starting position
POS[C] = AC (1500) Rotary axis C traverses to position 1500
Absolute programming along the shortest path (DC)

POS[axis name] = DC(value)
Even if the rotary axis is not defined as a modulo axis, the axis can still be positioned with DC
(Direct Control). The response is the same as on a modulo axis.
The value identifies the rotary-axis target position in a range from 0 to 359.999 (modulo
360). Alarm 16830, "Incorrect modulo position programmed", is output for values with a
negative sign or 360.
With DC (Direct Control), the rotary axis approaches the programmed absolute position
within one revolution along the shortest path (traversing movement max. 180).
The control calculates the direction of rotation and the traverse path according to the
current actual position (in relation to modulo 360). If the path to be traversed is the same
in both directions (180), the positive direction of rotation receives preference.
DC application example: the rotary table is required to approach the changeover position
in the shortest time (and, therefore, via the shortest path) possible.
If DC is programmed with a linear axis, alarm 16800, "DC traverse instruction cannot be
used", is output.
Example:
Programming Effect
POS[C] = AC (7200) Rotary axis C traverses to position 7200;
traversing direction depends on the starting position
POS[C] = DC(300) Rotary axis C approaches "modulo" position 300
along the shortest path
Thus, C traverses about 60 with a negative direction of rotation
and stops at absolute position 7140.
POS[C] = AC (7000) Rotary axis C traverses to position 7000 absolutely,
so C traverses about 140 with a negative direction of rotation
Note
In this example, it would be advisable to activate the modulo 360 display (MD30320
$MA_DISPLAY_IS_MODULO = 1).
Extended Functions
R2: Rotary axes
Incremental programming (IC, G91)

Example for positioning axis: POS[axis name] = IC(+/-value)
When programming with incremental dimensions, the rotary axis traverses across the same
path as with the modulo axis. In this case, however, the traversing range is limited by the
software limit switches.
The value identifies the rotary-axis traversing distance.
The value can be negative and +/-360.
The value's sign unequivocally defines the rotary-axis traversing direction.
Limited traversing range

The traversing range is limited as with linear axes. The range limits are defined by the "plus"
and "minus" software limit switches.
12.3.4 Other programming features relating to rotary axes
Offsets
TRANS (absolute) and ATRANS (additive) can be applied to rotary axes.
Scalings
SCALE or ASCALE are not suitable for rotary axes, since the control always bases its modulo
calculation on a 360 full circle.
Preset actual value memory

PRESETON is possible.
Indexing axes
See Section "T1: Indexing axes (Page 771)".
Extended Functions
R2: Rotary axes
12.4 Activating rotary axes
12.4 Activating rotary axes
Procedure
The procedure for activating rotary axes is the same as that for linear axes with a small
number of exceptions. It should be noted that, as soon as the axis is defined as a rotary axis
(MD30300 $MA_IS_ROT_AX = 1), the axis-specific-machine-/setting-data units are
interpreted by the control as follows:
Positions In "degrees"
Velocities In "rev/min"
Accelerations In "rev/sec2"
Jerk limitation In "rev/sec3"
Special machine data

Special rotary-axis machine data may also have to be entered, depending on the application:
MD30310 $MA_ROT_IS_MODULO Modulo conversion for positioning and

programming
MD30320 $MA_DISPLAY_IS_MODULO Modulo conversion for position display
MD10210 $MN_INT_INCR_PER_DEG Computational resolution for angular positions
The following overview lists the possible combinations of these machine data for a rotary
axis:
Possible combinations of rotary-axis machine data

MD30300 MD30310 MD30320 Application Comment
permitted
0 0 0 Yes The axis is a linear axis (default).
1 0 0 Yes The axis is a rotary axis; modulo
conversion is not used for positioning, i.e.
the software limit switches are active; the
position display is absolute.
1 0 1 Yes The axis is a rotary axis; modulo
conversion is not used for positioning, i.e.
the software limit switches are active; the
position display is modulo;
Application: for axes with an operating
range of +/-1000, for example
Extended Functions
R2: Rotary axes
12.5 Special features of rotary axes
Possible combinations of rotary-axis machine data

1 1 1 Yes The axis is a rotary axis; positioning is
performed with modulo conversion, i.e.
the software limit switches are inactive,
the operating range is unlimited; the
position display is modulo (setting most
frequently used for rotary axes); axis
with/without working-area limitation can
be used.
1 1 0 Yes The axis is a rotary axis; positioning is
performed with modulo conversion, i.e.
the software limit switches are inactive,
the operating range is unlimited; the
position display is absolute; axis
with/without working-area limitation can
be used.
0 0 or 1 0 or 1 Not Axis is not a rotary axis;
recommended therefore, the other MD are not evaluated.
JOG velocity for rotary axes

SD41130 $SN_JOG_ROT_AX_SET_VELO (JOG speed for rotary axes)
The above setting data can be used to define a valid JOG velocity for all rotary axes (see
also Section "H1: Manual and handwheel travel (Page 143)").
If a value of 0 is entered in the setting data, the following axial machine data acts as JOG
velocity for the rotary axis:
MD21150 $MC_JOG_VELO (conventional axis velocity)
12.5 Special features of rotary axes

The software limit switches and working-area limitations are active and are required for
swivel axes with a limited operating range. However, in the case of continuously rotating
rotary axes (MD30310 $MA_ROT_IS_MODULO = 1), the software limit switches and working
area limitations can be deactivated for individual axes.
A modulo rotary axis with/without working-area limitation can be used.
References:
Extended Functions
R2: Rotary axes
12.6 Examples
Mirroring of rotary axes

Mirroring can be implemented for rotary axes by programming MIRROR(C) or AMIRROR(C).

References:
Function Manual Basic Functions; Reference Point Approach (R1)
Spindles as rotary axes

For notes concerning the use of spindles as rotary axes (C axis operation), please refer to:
References:
12.6 Examples
Fork head, inclined-axis head

Rotary axes are frequently used on 5-axis milling machines to swivel the tool axis or rotate
the workpiece. These machines can position the tip of a tool on any point on the workpiece
and take up any position on the tool axis. Various milling heads are required, depending on
the application. The figure shows a fork head and an inclined-axis head as example rotary-
axis arrangements.
)RUNKHDG ,QFOLQHGD[LVKHDG
&
%
%
r r r
&
Figure 12-7 Fork head, inclined-axis head
Extended Functions
R2: Rotary axes
12.7 Data lists
12.7 Data lists
12.7.1 Machine data

10210 INT_INCR_PER_DEG Computational resolution for angular positions

30300 IS_ROT_AX Axis is rotary axis
30310 ROT_IS_MODULO Modulo conversion for rotary axis
30320 DISPLAY_IS_MODULO Modulo actual-value display
30330 MODULO_RANGE Modulo-range magnitude
30340 MODULO_RANGE_START Modulo-range starting position
30455 MISC_FUNCTION_MASK Axis functions
36100 POS_LIMIT_MINUS Minus software limit switch
36110 POS_LIMIT_PLUS Plus software limit switch
12.7.2 Setting data

41130 JOG_ROT_AX_SET_VELO JOG velocity for rotary axes

43420 WORKAREA_LIMIT_PLUS Plus working-area limitation
43430 WORKAREA_LIMIT_MINUS Minus working-area limitation
Extended Functions
R2: Rotary axes
12.7 Data lists
12.7.3 Signals

Traversing-range limitation for modulo axis DB31, ... .DBX12.4 DB380x.DBX1000.4

Status of software-limit-switch monitoring for modulo axis DB31, ... .DBX74.4 DB390x.DBX1000.4
Extended Functions
R2: Rotary axes
12.7 Data lists
Extended Functions
S3: Synchronous spindle 13
13.1.1 Function
The "Synchronous spindle" function can be used to couple two spindles with synchronous
position or speed. One spindle is defined as leading spindle (LS), the second spindle is then
the following spindle (FS).
Speed synchronism: nFS = k * nLS with k = 1, 2, 3, ...

Position synchronism: FS = LS + with 0 x t = 360
Possible applications
Rear side machining
One application option is, for example, the reverse side machining in a double-spindle lathe
with on-the-fly transfer of the workpiece from the position-synchronous LS to the FS (or vice
versa), without having to decelerate down to standstill.
Multi-edge machining (polygonal turning)
The "Synchronous spindle" function provides the basis for multi-edge machining (polygonal
turning) through specification of an integer gear ratio k between LS and FS.
Number of FS
The number of FS's that can be operated synchronously to an LS is only restricted by the
performance capability of the NC used. In principle, any number of FS can be coupled
simultaneously to an LS in arbitrary channels of the NC.
2 pairs of synchronous spindles can be active simultaneously in each NC channel.
Definition
The assignment of FS to LS pair of synchronous spindles can be parameterized channel-
specifically via machine data or flexibly defined via part program commands.
Extended Functions
S3: Synchronous spindle
Selecting/de-selecting
Part program commands are used to select/deselect the synchronous operation of a pair of
synchronous spindles.
&KXFNV
Q Q
6SLQGOH 6SLQGOH
Q Q
6SLQGOH
6SLQGOH
Q Q
6SLQGOH 6SLQGOH
Figure 13-1 Synchronous operation: On-the-fly workpiece transfer from spindle 1 to spindle 2
Extended Functions
Q Q
6SLQGOH 6SLQGOH
Figure 13-2 Synchronous operation: Polygonal turning
13.1.2 Synchronous mode
Description
<axial expression>: can be:

- Axis name
- Spindle name
<axis name>: C (if spindle has the name "C" in axis operation.)
<spindle name>: Sn, SPI(n) where n = spindle number
<Spindle number>: 1, 2, ... according to the spindle number defined
in MD35000
$MA_SPIND_ASSIGN_TO_MACHAX
(FS, LS, offset): LS = Leading Spindle, FS = Following
Spindle,Offset = read programmable offset of
following spindle using system variables
$P_COUP_OFFS[Sn] Programmed position offset of the synchronous
spindle
Synchronous spindle pair

Synchronous operation involves a following spindle (FS) and a leading spindle (LS), referred
to as the synchronous spindle pair. The following spindle imitates the movements of the
leading spindle when a coupling is active (synchronous operation) in accordance with the
defined functional interrelationship.
Synchronous mode
Synchronous mode (also referred to as Synchronous spindle operation) is another spindle
operating mode. Before synchronous mode is activated, the following (slave) spindle must
have been switched to position control. Synchronous operation is activated for the following
spindle when the coupling is activated. As soon as the coupling is deactivated, the following
spindle switches back to open-loop control mode.
As soon as synchronous operation is active for the following spindle, the following interface
signal is reported to the PLC:
IS "Synchronous mode" (DB31, ... DBX84.4) = 1.
Extended Functions
Number of synchronous spindles

It is possible to couple several following spindles to one leading spindle. The number of
following spindles on this leading spindle depends on the respective version of the
appropriate software versions.
Any number of following spindles in any channels of one NCU or a different NCU can be
coupled to this leading spindle.
Note that one spindle is always the master and the number of couplings results from the
number of axes less the master.
Options in synchronous mode

The following functions are available for synchronous mode:
FS and LS turn at the same speed
(nFS = nLS; transformation ratio k = 1)
Rotation in the same or opposite direction between LS and FS
(can be defined positively or negatively using transformation ratio k)
Following and leading spindles rotate at different speeds
(nFS = k nLS; transformation ratio k 1)
Application: Polygonal turning
Settable angular position between FS and LS (FS = LS + )
The spindles run at synchronous speed with a defined angular offset between FS and LS
(position synchronous coupling).
Application: Shaped workpieces
Activation of synchronous operation between LS and FS can take place when the
spindles are in motion or at standstill.
The full functionality of the open-loop and position control modes is available for the
leading spindle.
When synchronous mode is not active, the FS and LS can be operated in all other
spindle modes.
The transformation ratio can also be altered when the spindles are in motion in active
synchronous mode.
With synchronous spindle coupling switched on, the offset of the FS to the LS (overlaid
movement) can be altered.
Extended Functions
Coupling options
Synchronous spindle couplings can be defined as
Permanently configured via channel-specific machine data
(hereinafter referred to as "permanently configured coupling") as well as
Freely defined using language commands (COUP...) in the part program
(hereafter referred to as "user defined coupling")
. The following variants are possible:
1. A fixed configuration for a coupling can be programmed via machine data. In addition, a
second coupling can be freely defined via the part program.
2. No coupling is configured via machine data. In this case, the couplings can be user-
defined and parameterized via the part program.
Separate following spindle interpolator

The separate following spindle interpolator allows a number of following spindles from
different channels or from another NCU to be coupled as defined by the user to a single
leading spindle. The following spindle interpolator is
COUPON or COUPONC activated and
COUPOF or COUPOFS deactivated
and is always located in the channel in which the COUPON, COUPONC command has been
programmed for the following spindle. If the following spindle to be activated was previously
programmed in another channel, COUPON/COUPONC initiates an axis replacement and fetches
the spindle into its own channel.
Certain synchronous spindle functions can be controlled from the PLC by means of coupling-
specific axial VDI interface signals. These signals act exclusively on the slave spindles and
do not affect the leading spindle (see Section "Controlling synchronous spindle coupling via
PLC (Page 716)").
Definition of synchronous spindles

Before synchronous operation is activated, the spindles to be coupled (FS, LS) must be
defined.
This can be done in two ways depending on the application in question:
1. Permanently configured coupling:
Machine axes that are to function as the following spindle (FS) and leading spindle (LS)
are defined in channel-specific MD 21300 $MC_COUPLE_AXIS_1[n].
The machine axes programmed as the LS and FS for this coupling configuration cannot
be altered by the NC part program.
If necessary, the coupling parameters can be modified with the NC part program.
Extended Functions
2. User-defined coupling:
Couplings can be created and altered in the NC part program with language command
"COUPDEF(FS, LS, ...)". If a new coupling relationship is to be defined, it may be necessary
to delete an existing user-defined coupling beforehand (with language command
COUPDEL(FS, LS)).
The axis names (Sn, SPI(n)) for the following and leading spindles must be programmed
with FS and LS for every language command COUP..., thus ensuring that the
synchronous spindle coupling is unambiguously defined.
The valid spindle number must then be assigned axis-specific machine data of a machine
axis:
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX.
IS "Following spindle active" (DB31, ... DBX99.1) and IS "Leading spindle active" (DB31, ...
DBX99.0) indicate to the PLC for each machine axis whether the axis is active as a leading
or following spindle.
The LS can be programmed either via a part program, PLC or also using synchronized
actions.
Transformation ratio
The transformation ratio is programmed with separate numerical values for numerator and
denominator (transformation ratio parameters). It is therefore possible to specify the
transformation ratio very exactly, even with rational numbers.
In general:
k = transformation ratio parameter for numerator Transformation ratio parameters for
denominator = numerator : denominator
The value range of the transformation ratio parameter (numerator, denominator) is virtually
unlimited in the control.
The transformation ratio parameters for the coupling configured via machine data can be
defined in channel-specific SD42300: COUPLE_RATIO_1[n]. In addition, the transformation
ratio can be altered with language command COUPDEF(FS, LS, numerator, denominator ,...). The
values entered in the setting data is not overwritten in this case (default settings).
The transformation ratio for the coupling defined via the NC part program can only be input
with language command COUPDEF (...).
The new transformation ratio parameters take effect as soon as the COUPDEF command has
been processed.
For further programming commands for synchronous spindle couplings, please see
"Programming of synchronous spindle couplings" Section .
Extended Functions
Coupling characteristics
The following characteristics can be defined for every synchronous spindle coupling:
Block change behavior
The condition to be fulfilled for a block change can be defined on activation of
synchronous operation or on alteration of the transformation ratio or the defined angular
offset when the coupling is active:
Block change takes place immediately
Block change in response to "Fine synchronism"
Block change in response to "Coarse synchronism"
Block change for IPOSTOP (i.e. after setpoint-end synchronism)
Check of the synchronism conditions at an arbitrary moment with WAITC.
Type of coupling between FS and LS
The position setpoint or the actual position value of the leading spindle can be used as
the reference value for the following spindle. The following coupling types can therefore
be selected:
Setpoint coupling (DV)
Use in position controlled operation. The control dynamic response of both spindles
should coincide as far as possible. Preferably, the setpoint coupling should be used.
Actual value coupling (AV)
Application if no position control of the LS is possible or with great deviation of the
control characteristics between FS and LS. The setpoints for the FS are derived from
the actual values of the LS. The quality of synchronism is worse with a varying spindle
speed than with the setpoint coupling.
Speed coupling (VV)
Internally, the velocity coupling is a setpoint coupling. The requirements for FS and LS
are lower. Position control and measuring systems are not required for FS and LS.
The position offset between FS and LS is undefined.
The selection of the relevant coupling characteristics for the configured coupling is made
using machine data (see Section "Configuration (Page 728)") and for the user defined
coupling using the COUPDEF language command (see Section "Definition (COUPDEF)
(Page 721)").
In addition, coupling characteristics Type of coupling and Block change response can be
altered for the permanently configured coupling by means of language command COUPDEF.
References:
Programming Manual, Production Planning ("Synchronous Spindles").
Extended Functions
Change protection for coupling characteristics

The channel-specific MD21340 $MC_COUPLE_IS_WRITE_PROT_1 is used to define
whether or not the configured coupling parameters Transformation ratio, Type of coupling
and Block change response can be altered by the NC part program:
0: Coupling parameters can be altered by the NC part program via command COUPDEF
1: Coupling parameters cannot be altered by the NC part program. Attempts to make
changes will be rejected with an alarm message.
Superimposed motion
In synchronous operation, the synchronous spindle copies the movement of the leading
spindle in accordance with the programmed transformation ratio.
At the same time, the synchronous spindle can also be traversed with overlay so that the LS
and FS can operate at a specific angular position in relation to one another.
The overlaid traversing movement of the FS can be initiated in various ways:
Programmable position offset of FS for AUTOMATIC and MDA:
The COUPON and SPOS language commands can be used for active synchronous
operation to change the position reference between FS and LS (see Section
"Selecting synchronous mode for a part program (Page 712)").
Manual position offset of FS:
In JOG (JOG continuous or JOG incremental) mode
Superimposition of FS using the handwheel or with plus or minus traversing keys
when synchronous operation is active.
In AUTOMATIC and MDA modes
Superimposition of FS with handwheel using DRF offset
As soon as the FS executes the overlaid traversing movement, IS "Overlaid movement"
(DB31, ... DBX98.4) is set to the 1 signal.
The overlaid movement is executed optimally in terms of time at the maximum possible FS
speed with COUPON. With an offset change by means of SPOS, the positioning velocity can be
specified with FA[Sn] and manipulated by an override (can be selected through IS "Feedrate
override valid for spindle" DB31, ... DBX17.0).
Note
For more information about specifying the position speed with FA[Sn]:
References:
Function Manual, Basic Functions; Spindles (S1), "Spindle modes, positioning operations"
section
Extended Functions
Setpoint correction
The setpoint correction of the system variable $AA_COUP_CORR[Sn] impacts on all
subsequent following spindle programming in the same way as a position offset and
corresponds to a DRF offset in the MCS.
Example: establish correction value

If a coupling offset of 7 has been programmed using COUPON(....,77) and if a mechanical
offset of 81 has come about as a result of closing the workpiece support fixture, a correction
value of 4 is calculated:
The system variables return the following values for the following spindle:
$P_COUP_OFFS[S2] ; programmed position offset = 77
$AA_COUP_OFFS[S2] ; setpoint position offset = 77
$VA_COUP_OFFS[S2] ; actual value position offset approx. 77
$AA_COUP_CORR[S2] ; correction value = 4
13.1.3 Prerequisites for synchronous mode
Conditions on selection of synchronous mode

The following conditions must be fulfilled before the synchronous spindle coupling is
activated or else alarm messages will be generated.
The synchronous spindle coupling must have been defined beforehand (either
permanently configured via machine data or according to user definition via part program
using COUPDEF).
The spindles to be coupled must be defined in the NC channel in which the coupling is
activated.
Channel-spec. MD20070 $MC_AXCONF_MACHAX_USED
axis spec. MD35000 $MA_SPIND_ASSIGN_TO_MACHAX
The following spindle must be assigned to the NC channel in which the coupling is
activated.
Default setting with axis-specific MD30550 AXCONF_ASSIGN_MASTER_CHAN
The following applies to setpoint and actual value couplings (DV, AV):
FS and LS must at least have a position measuring system for recording positions and
position controls must be started up.
Note
When position control is activated, the maximum setpoint speed of the LS is automatically
limited to 90% (control reserve) of the maximum speed. The limitation is signaled via IS
"Setpoint speed limited" (DB31, ... DBX83.1).
Extended Functions
References:
Function Manual, Basic Functions; Spindles (S1)
The following applies to setpoint couplings (DV):
To ensure more accurate synchronization characteristics, the LS should be in position
control mode (language instruction SPCON) before the coupling is activated.
Before selecting the synchronous mode, the gear stage necessary for FS and LS must be
selected. In synchronous mode, gear stage changeover and therefore oscillation mode
are not possible for FS and LS. Upon request, an alarm message is generated.
Cross-channel coupling
The LS can be located in any channel.
The LS can be exchanged between channels by means of "Axis exchange".
When several following spindles are coupled to one leading spindle, the dynamic
response of the coupling is determined by the weakest response as a function of the
coupling factor. The acceleration rate and maximum speed are reduced for the leading
spindle to such a degree that none of the coupled following spindles can be overloaded.
The following spindle is always located in the channel in which the coupling has been
activated using COUPON or COUPONC.
13.1.4 Selecting synchronous mode for a part program
Activate coupling COUPON, COUPONC

Language command COUPON activates the coupling in the part program between the
programmed spindles with the last valid parameters and thus also activates synchronous
mode. This coupling may be a fixed configuration or user-defined. The leading spindle and/or
following spindle may be at standstill or in motion at the instant of activation.
Certain conditions must be fulfilled before synchronous operation can be activated (see
Section "Prerequisites for synchronous mode (Page 711)").
The COUPONC command adopts the previous programmed direction of spindle rotation and
spindle speed for the following and leading spindle in the part program. It is not possible to
specify an angular offset.
COUPON activation variants

Two different methods can be selected to activate synchronous mode:
1. Fastest possible activation of coupling with any angular reference between leading and
following spindles.
COUPON(FS, LS)
2. Activation of coupling with a defined angular offset POSFS between leading and following
spindle. With this method, the angular offset must be programmed on selection.
COUPON(FS, LS, POSFS)
Extended Functions

Before synchronous operation is selected, it must be determined under what conditions the
block change must occur when synchronous mode is activated (see Section "Definition
(COUPDEF) (Page 721)").
Determine current coupling status

The $AA_COUP_ACT[<axial expression>] axial system variable can be used in the NC part
program to specify the current coupling status for the specified axis/spindle (see Section
"Axial system variables for synchronous spindle (Page 726)"). As soon as the synchronous
spindle coupling is active for the following spindle, bit 2 must be "1" when read.
Change defined angular offset

Language commands COUPON and SPOS allow the defined angular offset to be changed while
synchronous mode is active. The following spindle is positioned as an overlaid movement at
the angular offset programmed with POSFS. During this time, the IS "overlaid movement"
(DB31, ... DBX98.4) is set.
Angular offset POSFS

The defined angular offset POSFS must be specified as an absolute position referred to the
zero degrees position of the leading spindle in a positive direction of rotation.
The "0 position" of a position-controlled spindle is calculated as follows:
From the zero mark or Bero signal of the measurement system and
From the reference values saved using axis-specific machine data:
MD34100 $MA_REFP_SET_POS, reference point value,
of no significance with interval-coded systems.
MD34080 $MA_REFP_MOVE_DIST reference point distance/target point
with interval-coded systems,
MD34090 $MA_REFP_MOVE_DIST_CORR reference point offset / absolute offset with
interval coding.
Range of POSFS: 0 ... 359,999.
References:
Function Manual Basic Functions; Reference Point Travel (R1)
Extended Functions
Read current angular offset

Using axial system variables, it is possible to read the current position offset between the FS
and LS in the NC part program. A distinction is made between:
Current position offset of setpoint between FS and LS
$AA_COUP_OFFS [<axis name for FS>]
Current position offset of actual value between FS and LS
$VA_COUP_OFFS [<axis name for FS>]
(Explanation of <axis name>, see Section "Synchronous mode (Page 705)")
Activation after power ON

Synchronous mode can also be activated with non-referenced/synchronized FS or LS (IS
"Referenced/synchronized 1 or 2" DB31, ... DBX60.4 or DBX60.5 = 0). In this case, a
warning message is displayed.
Example:
LS and FS are already coupled in a friction lock via a workpiece after power ON.
13.1.5 Deselecting the synchronous mode for the part program
Open coupling (COUPOF, COUPOFS)

Synchronous mode between the specified spindles is canceled by the parts program
instruction COUPOF. Three variants are possible.
If synchronous mode is canceled between the specified spindles using COUPOF, then it is
irrelevant whether this coupling is permanently configured or user defined. The leading and
following spindles can be at standstill or in motion when synchronous operation is
deactivated.
On switching off the synchronous mode with COUPOF, the following spindle is put into control
mode. The originally programmed S-word is no longer valid for the FS, the following spindle
can be operated like any other normal spindle.
When the coupling is opened with COUPOF, a block preprocessing stop STOPRE is generally
initiated internally in the control.
The COUPOFS instruction can be used to open a coupling either as quickly as possible with a
stop and no position data or with a stop at the programmed position.
COUPOF variants
Three different methods can be used to deselect synchronous mode with COUPOF:
1. Deactivation of coupling as quickly as possible
The block change is enabled immediately.
COUPOF(FS, LS)
Extended Functions
2. A coupling is not deselected until the following spindle has crossed the programmed
deactivation position POSFS.
The block change is then enabled.
COUPOF(FS, LS, POSFS)
3. A coupling is not deselected until the following spindle and leading spindle has crossed
the programmed deactivation positions POSFS and POSLS.
COUPOF(FS, LS, POSFS , POSLS)
POSFS, POSLS
Deactivation positions POSFS and POSLS match the actual positions of FS and LS
respectively referred to the defined reference point value.
Range of POSFS, POSLS: 0 ... 359,999.
References:
COUPOF during the motion

If synchronous mode is deselected while the spindles are in motion with COUPOF, the following
spindle continues to rotate at the current speed (nFS). The current speed can be read with
system variable $AA_S in the NC parts program.
The following spindle can then be stopped from the parts program with M05, SPOS, SPOSA or
from the PLC with the appropriate interface signal.
COUPOFS with stop of following spindle

Opening a synchronous spindle coupling is extended by a stop of the following spindle:
Deactivating a coupling as quickly as possible and opening a coupling as quickly as
possible.
COUPOFS(FS, LS)
Opening the coupling with stop of following spindle at the programmed position. The
block change is then enabled.
Condition:
COUPOFS(FS, LS) and COUPOFS(FS, LS, POSFS) have no meaning if a coupling was
active.
Extended Functions
13.1.6 Controlling synchronous spindle coupling via PLC
Controlling following spindle via PLC

Using the coupling-specific, axial VDI interface signals, it is possible to control
synchronization motions for the following spindle from the PLC program. This offers the
option of utilizing the PLC to disable, suppress or restore a synchronization motion for the
following spindle specified by offset programming.
These signals have no effect on the leading spindle. The following coupling-specific VDI
signal (PLC NCK) is available:
IS "Disable synchronization" (DB31, ... DBX31.5)
"Disable synchronization"
The synchronization motion for the following spindle is suppressed using the axial signal IS
"Disable synchronization" (DB31, ... DBX31.5).
When the main run advances to a block containing part program instruction COUPON (FS, LS,
offset), the following interface signal is evaluated for the following spindle:
IS "Disable synchronization" (DB31, ... DBX31.5).
For IS "Disable synchronization" (DB31, ... DBX31.5) = 0, the position offset is traversed
through as before.
For IS "Disable synchronization" (DB31, ... DBX31.5) = 1, only the continuous velocity
synchronism is established. The following spindle does not execute any additional
movement.
The coupling then responds analogously to a programmed COUPON(<FS>,<LS>).
Special features
For the IS "Disable synchronization" (DB31, ... DBX31.5) offset motion of the following
spindle cannot be controlled that was generated as follows:
SPOS, POS
Synchronized actions
FC18 (for 840D sl)
JOG
These functions are controlled by VDI signal IS "Feedrate stop/Spindle stop" (DB31, ...
DBX4.3).
Synchronized state reached

Whenever a state of synchronism has been reached, the following two VDI signals are set
regardless of whether synchronization has been disabled or not:
IS "Synchronism coarse" (DB31, ... DBX98.1) and
IS "Synchronism fine" (DB31, ... DBX98.0)
Further block changes after COUPON are not prevented by suppression of synchronization.
Extended Functions
Example
Block change behavior after COUPON

; IS "Disable synchronization"
; set (DB31, ... DBX31.5) = 1 for S2
N51 SPOS=10 SPOS[2]=10 ; Positions correspond to an offset
; of 0
N52 COUPDEF(S2,S1,1,1,"FINE","DV")
N53 COUPON(S2,S1,77) ; Actual offset of 0 degrees is retained
; no following spindle movement,
; VDI signals
; IS "Synchronism coarse"
; (DB31, ... DBX98.1) and
; IS "Synchronism fine"
; (DB31, ... DBX98.0)
; are set and the block change
; enabled.
N54 M0
N57 COUPOF(S2,S1)
N99 M30
Reset and recovery

Resetting the IS "Disable synchronization" (DB31, ... DBX31.5) has no effect on the following
spindle offset. If the offset motion of the following spindle has been suppressed by the VDI
interface signal, then the offset is not automatically applied when the VDI signal is reset.
Synchronization is recovered as follows:
By repeating the part program operation COUPON (FS, LS, offset) with IS "Disable
synchronization" (DB31, ... DBX31.5) = 0.
COUPON (FS, LS, offset) can be written e.g. in an ASUB.
By setting the IS "Resynchronize" (DB31, ... DBX31.4) = 1
Extended Functions
Read offset
The following system variables can be used to read three different position offset values of
the following spindle from the part program and synchronized actions. The variable
$P_COUP_OFFS[Sn] is only available in the part program.
Description NCK variable

Programmed position offset of the synchronous spindle $P_COUP_OFFS[Sn]
Position offset of synchronous spindle, setpoint end $AA_COUP_OFFS[Sn]
Position offset of synchronous spindle, actual value end $VA_COUP_OFFS[Sn]
"Feedrate stop/spindle stop"

By configuring bit 4 in MD30455 MISC_FUNCTION_MASK, the behavior of the axial IS
"Feedrate stop/Spindle stop" (DB31, ... DBX4.3) is defined for the following spindle.
Bit 4 = 0 compatibility method:
Canceling feed enable for the following spindle decelerates the coupling assembly.
Bit 4 = 1:
Feedrate enable refers only to the interpolation component (SPOS),..) and does not affect
the coupling.
Note
Other configuration options for axis functions using MD30455
$MA_MISC_FUNCTION_MASK:
References:
Function Manual, Basic Functions; Rotary Axes (R2), Section: Programming rotary axes
13.1.7 Monitoring of synchronous operation
Fine/coarse synchronism
In addition to conventional spindle monitoring operations, synchronous operation between
the FS and LS is also monitored in synchronous mode.
IS "Fine synchronism" (DB31, ... DBX98.0) or IS "Coarse synchronism" (DB31, ... DBX98.1)
is transmitted to the PLC to indicate whether the current position (AV, DV) or actual speed
(VV) of the following spindle lies within the specified tolerance window.
When the coupling is switched on, the signals "Coarse synchronism" and "Fine synchronism"
are updated when setpoint synchronism is reached.
Extended Functions
The size of the tolerance windows is set with machine data of the FS. Reaching of the
synchronism is influenced by the following factors:
AV, DV: Position variance between FS and LS
VV: Difference in speed between FS and LS
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synchronization on a turning leading spindle
Extended Functions
13.2 Programming
Threshold values
The relevant position or velocity tolerance range for the following spindle in relation to the
leading spindle must be specified in degrees or 1 rev/min.
Threshold value for "Coarse synchronism"
axis spec. MD37200: AV, DV: COUPLE_POS_TOL_COARSE
MD37220: VV: COUPLE_VELO_TOL_COARSE
Threshold value for "Fine synchronism"
axis spec. MD37210: AV,DV: COUPLE_POS_TOL_FINE
MD37230: VV: COUPLE_VELO_TOL_FINE
Speed/acceleration limits
In synchronous mode, the speed and acceleration limit values of the leading spindle are
adjusted internally in the control in such a way that the following spindle can imitate its
movement, allowing for the currently selected gear stage and effective speed ratio, without
violating its own limit values.
For example, the LS is automatically decelerated to prevent the FS from exceeding the
maximum speed in order to maintain synchronism between the spindles.
13.2 Programming
Coupling commands with leading-spindle programming
Command Function
COUPDEF(FS, LS, ...) Define coupling or change for configured coupling
COUPON(FS, LS, POSFS) Switch the coupling on
COUPONC(FS, LS) Activate coupling with transfer of the currently effective
speed of the following spindle
COUPOF(FS, LS, POSFS, POSLS) Switch the coupling off
COUPOFS(FS, LS, POSFS) Deactivate coupling with stop of the following spindle
COUPDEL (FS, LS) Delete coupling
COUPRES (FS, LS) Reactivate configured coupling data
Coupling commands without leading-spindle programming
Command Function
COUPOF(FS, POSFS, POSLS) Switch the coupling off
COUPOFS(FS, POSFS) Deactivate coupling with stop of the following spindle
COUPDEL(FS) Delete coupling
COUPRES(FS) Reactivate configured coupling data
Extended Functions
13.2 Programming
See also
Definition (COUPDEF) (Page 721)
Switch the coupling (COUPON, COUPONC, COUPOF) on and off (Page 724)
13.2.1 Definition (COUPDEF)
Programmable couplings
The number of couplings can be programmed as often as desired depending on the axes
available. This number results from the number of axes/spindles less one for the master.
Furthermore, one coupling can also be configured via machine data as in earlier SW
versions.
Permanently configured coupling

The coupling characteristics and transformation ratio for a permanently configured
synchronous spindle coupling can be altered by the NC part program provided that they are
not write-protected. The machine axes for LS and FS cannot be changed.
Define new couplings

Language command "COUPDEF" can be used to create new synchronous spindle couplings
(user-defined) and to modify the parameters for existing couplings.
When the coupling parameters are fully specified, the following applies:
COUPDEF(FS, LS, Tnumerator, Tdenominator, block change behavior, coupling type)
The synchronous spindle coupling is unambiguously defined with FS and LS
The other coupling parameters must only be programmed when they need to be changed.
The last valid status remains applicable for non-specified parameters.
The individual coupling parameters are explained below:
FS, LS: Spindle name for following and leading spindles
e.g.: S1, SPI(1), S2, SPI(2)
The valid spindle number must be assigned in the axis-specific MD35000
$MA_SPIND_ASSIGN_TO_MACHAX of a machine axis.
Tnumerator, Tdenominator: Transformation ratio parameters for numerator and denominator
The transformation ratio is specified in the form of numeric values for numerator and
denominator (see Section "Synchronous mode (Page 705)").
The numerator must always be programmed. If no denominator is specified, then its
value is always assumed to be "1.0".
Extended Functions
13.2 Programming

This parameter allows you to select when the block change should take place when
synchronous operation is selected:
NOC: Block change is enabled immediately
FINE: Block change in response to "Fine synchronism"
COARSE: Block change in response to "Coarse synchronism"
IPOSTOP: Block change for IPOSTOP (i.e. after setpoint-end synchronism)
The block change response is specified as a character string (i.e. with quotation marks).
The block change response can be specified simply by writing the letters in bold print. The
remaining letters can be entered to improve legibility of the part program but they are not
otherwise significant.
If no block change response is specified, then the currently selected response continues to
apply.
With the programmable synchronism test markers WAITC, the replacement with new blocks
is delayed until the parameterized synchronism is reached.
Coupling type
DV (Desired Values): Setpoint coupling between FS and LS
AV (Actual Values): Actual value coupling between FS and LS
VV (Velocity Values): Speed coupling between FS and LS
If no coupling type is specified, then the currently selected type continues to apply.
Note
The coupling type may only be changed when synchronous operation is deactivated!
Examples
COUPDEF (SPI(2), SPI(1), 1.0, 1.0, "FINE", "DV")
COUPDEF (S2, S1, 1.0, 4.0)
COUPDEF (S2, SPI(1), 1.0)
Default settings
The following default settings apply to user-defined couplings:
Numerator=1.0
Denominator =1.0
Block change response = IPOSTOP (block change enabled with setpoint synchronism)
Type of coupling = DV (setpoint coupling)
Extended Functions
13.2 Programming
Delete couplings
Language command "COUPDEL" is used to delete user-defined couplings.
COUPDEL (FS, LS)
Note
COUPDEL impacts on an active coupling, deactivates it and deletes the coupling data. Alarm
16797 is therefore meaningless.
The following spindle adopts the last speed. This corresponds to the behavior associated
with COUPOF(FS, LS).
Activate original coupling parameters

Language command "COUPRES" can be used to re-activate the configured coupling
parameters.
COUPRES (FS, LS)
The parameters modified using COUPDEF (including the transformation ratio) are subsequently
deleted.
Language command "COUPRES" activates the parameters stored in the machine and setting
data (configured coupling) and activates the default settings (user-defined coupling).
Programmable block change

It is possible to mark a point in the NC program using the "WAITC" language command. The
system waits at this point for fulfillment of the synchronism conditions for the specified FS
and delays changes to new blocks until the specified state of synchronism is reached (see
"Figure 13-3 Synchronism monitoring with COUPON and synchronism test mark WAITC with
synchronization on a turning leading spindle (Page 719)").
WAITC (FS)
Advantage: The time between activating the synchronous coupling and reaching
synchronism can be used in a meaningful way, technologically speaking.
Note
Basically, it is always possible to write WAITC. If the spindle indicated is not active as FS,
the command for this spindle is without effect.
If no synchronism condition is indicated, the check is always performed for the synchronism
condition programmed/configured on the respective coupling, at least for the setpoint
synchronism.
Extended Functions
13.2 Programming
Examples:
WAITC(S2),
:
WAITC(S2, "Fine"),
:
WAITC(S2, ,S4, "Fine")
Stop and block change

If "Stop" has been activated for the cancellation period of the axis enables for the leading or
following spindle, then the last setpoint positions with the setting of the axis enables from
the servo drive are approached again.
Commands COUPON and WAITC can influence the block change behavior. The block change
criterion is defined using COUPDEF or via the MD21320
$MC_COUPLE_BLOCK_CHANGE_CTRL_1.
13.2.2 Switch the coupling (COUPON, COUPONC, COUPOF) on and off
Activate synchronous mode

Language command COUPON is used to activate couplings and synchronous mode.
Two methods by which synchronous operation can be activated are available:
1. COUPON(FS, LS)
Fastest possible activation of synchronous operation with any angular reference between
the leading and following spindles.
2. COUPON(FS, LS, POSFS)
Activation of synchronous operation with a defined angular offset POSFS between the
leading and following spindles. This offset is referred to the zero degrees position of the
leading spindle in a positive direction of rotation. The block change is enabled according
to the defined setting. Range of POSFS: 0 ... 359.999 degrees.
3. COUPONC(FS, LS)
When activating with COUPONC, the previous programming of M3 S... or M4 S... is adopted.
A difference in speed is transferred immediately. An offset position cannot be
programmed.
By programming COUPON(FS, LS, POSFS) or SPOS when synchronous operation is already
active, the angular offset between LS and FS can be changed.
Extended Functions
13.2 Programming
Deactivate synchronous mode

Three different methods can be selected to deactivate synchronous mode:
1. COUPOF(FS, LS)
Fastest possible deactivation of synchronous operation. The block change is enabled
immediately.
2. COUPOF(FS, LS, POSFS)
Deselection of synchronous operation after deactivation position POSFS has been
crossed. Block change is not enabled until this position has been crossed.
3. COUPOF(FS, LS, POSFS, POSLS)
Deselection of synchronous operation after the two deactivation positions POSFS and
POSLS have been crossed. Block change is not enabled until both programmed positions
have been crossed.
Range of POSFS, POSLS: 0 ... 359,999.
If continuous path control (G64) is programmed, a non-modal stop is generated internally in
the control.
Examples:
COUPDEF (S2, S1, 1.0, 1.0, "FINE, "DV")
:
COUPON (S2, S1, 150)
:
COUPOF (S2, S1, 0)
:
COUPDEL (S2, S1)
1. COUPOFS(FS, LS)
Deactivating a coupling with stop of the following spindle. Block change is performed as
quickly as possible with immediate block change.
2. COUPOFS(FS, LS, POSFS)
After the programmed deactivation position that refers to the machine coordinate system
has been crossed, the block change is not enabled until the deactivation positions
POSFS have been crossed.
Value range 0 ... 359.999.
Extended Functions
13.2 Programming
13.2.3 Axial system variables for synchronous spindle
Determining current coupling status

The current coupling status of the following spindle can be read in the NC part program with
the following axial system variable:
$AA_COUP_ACT[<axial expression>]
For explanation of <axial expression>, see Section "Synchronous mode (Page 705)".
Example:
$AA_COUP_ACT[S2]
The value read has the following significance for the following spindle:
Byte = 0: No coupling active

Bit 2 = 1: Synchronous spindle coupling active
Bit 2 = 0: Synchronized spindle coupling is not active
Read current angular offset

The current position offset between the FS and LS can be read in the NC part program by
means of the following axial system variables:
Setpoint-based position offset between FS and LS:
$AA_COUP_OFFS[<axial expression>]
Actual-value-based position offset between FS and LS:
$VA_COUP_OFFS[<axial expression>]
Example:
$AA_COUP_OFFS[S2]
If an angular offset is programmed with COUPON, this coincides with the value read after
reading the setpoint synchronization.
Reading the programmed angular offset

The position offset last programmed between the FS and LS can be read in the NC part
program by means of the following axial system variables:
$P_COUP_OFFS[<axial expression>]
Note
After cancellation of the servo enable signal when synchronous operation and follow-up
mode are active, the position offset applied when the controller is enabled again is different
to the originally programmed value.
$P_COUP_OFFS only returns the value originally programmed. $AA_COUP_OFFS and
$VA_COUP_OFFS return the current value. The programmed offset can be recreated with
NST DB31, ... DBX31.4 (resynchronization).
Extended Functions
13.2 Programming
13.2.4 Automatic selection and deselection of position control
Behavior in speed control mode

In DV coupling mode, program instructions COUPON, COUPONC and COUPOF, COUPOFS are used to
activate and/or deactivate position control for the leading spindle as required. If there are
several following spindles on the leading spindle, then in speed-controlled mode, the first
DV activates coupling position control for the leading spindle and the last DV coupling
deactivates coupling position control for the leading spindle if SPCON is not programmed.
The leading spindle does not need to be located in the same channel as the following
spindle.
Automatic selection with COUPON and COUPONC

Depending on the coupling type, the effect of COUPON and COUPONC on the position control for
synchronous operation is as follows:
Coupling type DV AV VV
Following spindle FS Position control ON Position control ON No action
Leading spindle LS Position control On 1 No action No action
1 The position control is activated by a COUPON and COUPONC instruction if at least one
following spindle has been coupled to it with coupling type DV.
Automatic deselection with COUPOF and COUPOFS

Depending on the coupling type, the effect of COUPOF and COUPOFS on the position control is
as follows:
Coupling type DV AV VV
Following spindle FS Position control OFF 2 Position control OFF 2 No action 2
Leading spindle LS Position control OFF 3 No action No action
2COUPOF and COUPOFS without position specification
Speed control mode is activated for the following spindle. Positioning mode is activated with
COUPFS with a stop position. Position control is not deactivated if the following spindle was
located in position-controlled spindle mode using SPCON or COUPFS was programmed with
position.
3With COUPOF position control is deactivated if there are no more couplings of the DV
coupling type for this leading spindle. Position control is retained if the leading spindle is in
positioning mode or axial mode or was in position-controlled spindle mode using SPCON.
Extended Functions
13.3 Configuration
13.3 Configuration
Note
One synchronous-spindle coupling can be configured for each channel.
Table 13- 1 Machine data
Number Name: $MC_ Function

MD21300 COUPLE_AXIS_1[<n>] Machine axes of the synchronous-spindle coupling:
<n> = 0: Machine axis number of the following spindle
<n> = 1: Machine axis number of the leading spindle
Machine axis numbers in accordance with: MD20070
$MC_AXCONF_MACHAX_USED (machine axes in the channel)
Machine axis numbers == 0: No coupling configured. The following system data
is then not relevant.
Note: The machine axes configured for the synchronous-spindle coupling cannot
be changed using program commands.
MD21320 COUPLE_BLOCK_ Block change release after activating the synchronous operation 1):
CHANGE_CTRL_1
Immediately
On reaching "Synchronism fine"
On reaching "Synchronism coarse"
On reaching "Synchronism setpoint"
Note: No change protection1), the block change release can be changed with the
COUPDEF command.
MD21310 COUPLING_MODE_1 Coupling type 1):
Actual value coupling
Setpoint value coupling
Speed coupling
Note: No change protection1), the coupling type can be changed for deactivated
coupling with the COUPDEF command.
MD21330 COUPLE_RESET_ Behavior of the synchronous-spindle coupling with regard to NC Start, NC Stop
MODE_1 and Reset.
MD21340 COUPLE_IS_WRITE_ Change protection for coupling
PROT_1
1) See MD21340 $MC_COUPLE_IS_WRITE_PROT_1
Table 13- 2 Setting data
Number Name: $SC_ Function

SD42300 COUPLE_RATIO_1[<n>] Speed transmission ratio: FS / LS = numerator / denominator 1):
<n> = 0: Numerator (FS)
<n> = 1: Denominator (LS)
Note: No change protection1), the transmission ratio can be changed with the
COUPDEF command.
1) See MD21340 $MC_COUPLE_IS_WRITE_PROT_1
Extended Functions
13.3 Configuration
13.3.1 Response of the synchronous-spindle coupling for NC Start

The behavior of the synchronous-spindle coupling during NC Start depends on the setting in
the following machine data:
Configured synchronous-spindle coupling
Response MD21330 $MC_COUPLE_RESET_MODE_1

Maintain coupling Bit 0 = 0
Deselect coupling Bit 0 = 1
Activate configured data Bit 5 = 1
Switch the coupling on Bit 9 = 1
Programmed synchronous-spindle coupling
Response MD20112 $MC_START_MODE_MASK

Maintain coupling Bit 10 = 0
Deselect coupling Bit 10 = 1
13.3.2 Behavior of the synchronous-spindle coupling for reset

The behavior of the synchronous operation for reset and at program end depends on the
setting in the following machine data:
Configured synchronous-spindle coupling
Response MD21330 MD20110

$MC_COUPLE_RESET_ $MC_RESET_MODE_MASK
MODE_1
Maintain coupling Bit 1 = 0 Bit 0 = 1
Deselect coupling Bit 1 = 1 Bit 0 = 1
Activate configured data Bit 6 = 1 Bit 0 = 1
Programmed synchronous-spindle coupling
Maintain coupling Bit 0 = 1, Bit 10 = 1
Deselect coupling Bit 0 = 1, Bit 10 = 0
Extended Functions
13.4 Points to note
13.4 Points to note
13.4.1 Special features of synchronous mode in general
Control dynamics
When using the setpoint coupling, the position control parameters of FS and LS (e.g. KV
factor) should be matched with one another. If necessary, different parameter blocks should
be activated for speed control and synchronized mode. The control parameters of the
following spindle may differ from position control, feedforward control and parameter block,
as also in the uncoupled case, set using MD30455 $MA_MISC_FUNCTION_MASK (see
Section "Special points regarding start-up of a synchronous spindle coupling (Page 743)").
Precontrol
Due to the improved control system dynamic response it provides, feedforward control for
the following and leading spindles in synchronous mode is always active.
It can, however, be deselected for FS and LS with axis-specific MD32620
$MA_FFW_MODE. If MD32620 $MA_FFW_MODE is set to zero, there are function
limitations. Position control can no longer be activated in motion with SPCON. SPOS, M19 or
SPOSA are therefore not possible. The NC part program cannot deactivate the feedforward
control for LS and FS with FFWOF.
The feedforward control mode (speed or torque feedforward control) is defined in axis-
specific MD32620 $MA_FFW_MODE (see also Section "K3: Compensations (Page 223)").
Speed and acceleration limits

The speed and acceleration limits of the spindles operating in synchronous mode are
determined by the "weakest" spindle in the synchronous spindle pair. The current gear
stages, the programmed acceleration and, for the leading spindle, the effective position
control status (On/Off) are taken into account for this purpose.
The maximum speed of the leading spindle is calculated internally in the control taking into
account the speed ratio and the spindle limitations of the following spindle.
Multiple couplings
If the system detects that a coupling is already active for an FS and LS when the
synchronous mode is activated, then the activation process is ignored and an alarm
message is generated.
Examples of multiple couplings:
A spindle is acting as the FS for several LS.
Coupling cascade (an FS is an LS of an additional coupling)
Extended Functions
13.4 Points to note
Number of configurable spindles per channel

Every axis in the channel can be configured as a spindle. The number of axes per channel
depends on the control version.
Cross-channel setpoint coupling

Cross-channel synchronous spindle couplings can be implemented with no additional
restrictions for DV, AV, and VV.
Any number of following spindles, corresponding to the number of all spindles minus one
spindle for the master, in any channels on an NCU can be coupled to one leading
spindle.
Start synchronous mode using ASUB

When the PLC starts an ASUB, in the AUTOMATIC or MDA modes, synchronous operation
can be switched on and off or terminated.
References:
Function Manual, Basic Functions, Mode Group, Channel, Program Operation, Reset
Behavior (K1)
Response to alarms
In the case of an alarm, which occurs during synchronous operation, and acts as alarm
response "withdraw control enable" and "activate follow-up mode" in the control, the ongoing
control behavior is the same as the behavior due to NC/PLC interface signals:
DB31, ... DBX2.1 = 0 (controller enable)
DB31, ... DBX1.4 = 1 (follow-up mode)
(See Section "Synchronous mode and NC/PLC interface signals (Page 734)")
By resynchronizing via the NC/PLC interface signal:
DB31, ... DBX31.4 = 0 1 (resynchronization)
If the programmed offset is restored (see Section "Restore synchronism of following spindle
(Page 732)").
Block search when synchronous operation is active
Note
When synchronous operation is active for a block search, then it is recommended that only
block search type 5, "Block search via program test" (SERUPRO), is used.
Extended Functions
13.4 Points to note
13.4.2 Restore synchronism of following spindle
Causes for a positional offset

When the coupling is reactivated after the drive enable signals have been canceled, a
positional offset can occur between the leading and following spindles if follow-up mode is
activated. A positional offset can be caused by:
A part has been clamped or both spindles have been turned manually (machine area is
open, drives are disconnected from supply).
After the spindle enable signals are canceled, the two spindles coast to standstill at
different speeds if they are not mechanically coupled.
A drive alarm occurs (internal follow-up mode):
DB31, ... DBX61.3 (follow-up mode active) = 1
When the alarm is cleared, the NC must not trigger any synchronization motion.
A synchronization was not executed due to a synchronization lock of the following
spindle:
DB31, ... DBX29.5 (Disable synchronization)
Basic procedure
If the following and leading spindles have fallen out of synchronism, or failed to synchronize
at all, synchronism can be restored between them by the following measures:
1. Set the axis enable signals and cancel synchronization disable signal if this has been set.
2. Start following spindle resynchronization with the NC/PLC interface signal:
DB31, ... DBX31.4 (resynchronization)
Only after the resynchronization process is complete can the setpoint-end synchronism
be fully restored.
3. Wait until the coupled spindles have synchronized.
Enable resynchronization
Setting the enabling signals closes the coupling at the current actual positions. The two
following NC/PLC interface signals are set:
DB31, ... DBX98.1 (coarse synchronism)
DB31, ... DBX98.0 (fine synchronism)
The following requirements must be fulfilled for resynchronization to work:
The axis enabling signal must be set for the following spindle.
The PLC must not set any synchronization disables for the following spindle:
DB31, ... DBX31.5 (Disable synchronization)
Extended Functions
13.4 Points to note
Resynchronize following spindle

Resynchronization is started for the relevant following spindle and commences as soon as
the low-high edge of following interface signal is detected:
DB31, ... DBX31.4 (resynchronization)
The NC acknowledges the detection of the edge by outputting the NC/PLC interface signal:
DB31, ... DBX99.4 (synchronization running)
The interface signal "Synchronization running" is reset if:
synchronization of the following spindle has been completed up to the stage at which
there is synchronism at the setpoint end.
the NST DB31, ... DBX31.4 (resynchronization) was reset.
Response of synchronous signals during additional movements for the following spindle
The superimposed component is calculated to establish the synchronism signals.
Example

N51 SPOS=0 SPOS[2]=90
N52 OUPDEF(S2,S1,1,1,"FINE","DV")
N53 COUPON(S2,S1,77)
N54 M0 ; Offset=77, "coarse", "fine"
synchronous run signals exist.
N55 SPOS[2]=0 FA[S2]=3600 ; Difference in speed, synchronism
signals "coarse", "fine" are reported
N56 M0 ; (note tolerances, see above)
; Offset=0, "coarse", "fine" synchronous
run signals exist.
N60 M2=3 S2=500 ; difference in speed, synchronism
signals "coarse", "fine" are reported.
; offset undefined, synchronism signals
"coarse", "fine" are reported.
N65 M0 ; (Note tolerances, see above)
Note
The axis enable signals can be canceled to interrupt a movement overlaid on the following
spindle (e.g. SPOS). This component of the movement is not affected by IS "NC/PLC
interface signal" DB31, ... DBX31.4 (resynchronization), but is restored by the REPOS
operation.
Extended Functions
13.4 Points to note
Supplementary condition
IS DB31, ... DBX31.4 (resynchronization) has any effect only if there is a defined offset
position between the following spindle and leading spindle.
This is the case following COUPON with offset positions such as COUPON(...,77) or SPOS, SPOSA,
M19 for the following spindle with a closed coupling..
13.4.3 Synchronous mode and NC/PLC interface signals
Note
During synchronous operation, the effect of the associated interface signal for the leading
(LS) or following spindle (FS) on the coupling must always be considered.
Spindle override (DB31, ... DBB19)

Only the spindle compensation value of the LS acts in the synchronous operation.
Spindle disable (DB31, ... DBX1.3)
LS FS coupling Response
0 0 off Setpoints are output
0 1 off No setpoint output for FS
1 0 off No setpoint output for LS
1 1 off No setpoint output for LS and FS
0 0 ON Setpoints are output
0 1 ON Spindle disable not effective for FS
1 0 ON Spindle disable also effective for FS, no setpoint output
1 1 ON No setpoint output for LS and FS
Controller enable (DB31, ... DBX2.1)
LS: Resetting the "controller enable" during synchronous operation

If the controller enable of the LS is reset during synchronous operation for active setpoint
coupling, a control-internal switching is made to the actual value coupling. If the controller
enable is reset while the LS is traversing, the LS is stopped and an alarm issued.
Synchronous operation remains active.
LS and FS: Selection of synchronous operation without controller enable

If the "controller enable" for LS and FS is not set for selected synchronous operation, it will
be activated. LS and FS, however, are not traversed until controller enable for LS and FS
has been granted.
Extended Functions
13.4 Points to note
LS and FS: Setting the "Controller enable"

The position assumed by a spindle with setting the "controller enable" depends on DB31, ...
DBX1.4 == <value> (follow-up operation):
<value> Assumed spindle position

0 Position when controller enable is canceled
1 Current position
Note
It is recommended for synchronous spindles during a block search, to write the DB31, ...
DBX2.1 interface signal (controller enable) always together for FS and LS. If this is not done,
the block search, for example, stops after a FS machining because the controller enable of
the LS is not pending.
Note
Synchronism error
If the DB31, ... DBX2.1 interface signal (controller enable) is canceled for the FS after
Spindle Stop without the coupling being deactivated beforehand, then any synchronism error
resulting from external intervention will not be compensated when the "controller enable" is
activated again. This causes any programmed angular relationship between FS and LS to be
lost.
The angular relationship can be restored by resynchronizing: DB31, ... DBX31.4 = 1
(resynchronization)
Follow-up mode (DB31, ... DBX1.4)

For follow-up operation, the set position is regularly set to the current actual position:
DB31, ... DBX1.4 == 1 (follow-up operation) AND DB31, ... DBX2.1 == 0 (controller enable)
Cyclic: Set position = actual position
Note
DB31, ... DBX1.4 (follow-up operation) is relevant only for DB31, ... DBX2.1 == 0 (controller
enable)
Extended Functions
13.4 Points to note
Position measuring system 1/2 (DB31, ... DBX1.5 and 1.6)

Switchover of the position measuring system for the FS and LS is possible during
synchronous operation. The coupling is retained.
Note
It is recommended to switchover the position measuring system for FS and LS only for
deselected synchronous operation.
Delete distance-to-go / spindle reset (DB31, ... DBX2.2)
LS: Setting spindle reset during synchronous operation

The setting of spindle reset causes the LS to be braked to standstill with the parameterized
acceleration. Synchronous operation remains active.
Any superimposed movement, other than together with COUPON / COUPONC, will be completed
as fast as possible.
Spindle stop (feed stop) (DB31, ... DBX4.3)
LS and FS: Setting spindle stop during synchronous operation

The setting of "spindle stop" for FS or LS causes both spindles to be braked synchronous to
standstill. Synchronous operation remains active.
Resetting spindle stop

Once "spindle stop" has been reset for both spindles, reacceleration is made to the last valid
speed setpoint.
Application example
Bring FS and LS to a standstill when a protection door is opened during synchronous
operation.
Signal characteristic for LS and FS:
1. Stop: DB31, ... DBX4.3 = 1 (spindle stop)
2. Waiting for standstill: DB31, ... DBX61.4 == 1
3. Stopping: DB31, ... DBX2.1 = 0 (controller enable)
Delete S value (DB31, ... DBX16.7)
LS: Delete S value during synchronous operation

If "delete S value" is set, the LS is braked to a standstill using a ramp. Synchronous
operation remains active.
FS: Delete S value during synchronous operation

The control interface signal does not have any function for the FS in synchronous operation.
Extended Functions
13.4 Points to note
Resynchronize spindle 1/2 (DB31, ... DBX16.4 and 16.5)
LS: Resynchronizing the position measuring system during synchronous operation
Note
It is recommended to resynchronize the position measuring system of the LS only for
deselected synchronous operation.
Resynchronize (DB31, ... DBX31.4)
FS: Restoring the programmed angular offset

If synchronism between FS and LS is lost or not performed, the programmed angular offset
can be restored.
Requirement: DB31, ... DBX31.4 = 1 (resynchronization)
Acknowledgment: DB31, ... DBX99.4 == 1 (synchronization running)
Traverse keys for JOG (DB31, ... DBX4.6 and 4.7)

The "plus and minus traversing keys" for JOG are not disabled in the control for the FS in
synchronous operation, i.e. the FS executes a superimposed motion if one of these keys is
pressed.
Note
If superimposed traversing movements are to be precluded, they must be locked out by
measures in the PLC user program.
NC Stop axes plus spindles (DB21, ... DBX7.4)

"NC Stop axes plus spindles" in synchronous operation decelerates the coupled spindles in
accordance with the selected dynamic response. They continue to operate in synchronous
mode.
NC Start (DB21, ... DBX7.1)

(See Section "Response of the synchronous-spindle coupling for NC Start (Page 729)")
Note
NC Start after NC Stop does not deselect synchronous operation.
Extended Functions
13.4 Points to note
13.4.4 Differential speed between leading and following spindles
When does a differential speed occur?

A differential speed develops, e.g. with turning machine applications, when two spindles are
opposite each other. Through the signed addition of two speed sources, a speed component
is derived from the leading spindle via the coupling factor. In addition to this, it is possible to
program the following for the following spindle:
speed with S... and
direction of rotation with M3, M4 or M5
The spindles can normally be synchronized by a coupling factor with the value '-1'. This sign
reversal then results in a differential speed for the following spindle as compared to an
additional programmed speed. This typical behavior in relation to the NC is illustrated in the
following diagram.
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Figure 13-4 Schematic representation of process resulting in differential speed
Example

N01 M3 S500 ; S1 rotates positively at 500 rpm
; the master spindle is spindle 1
N02 M2=3 S2=300 , S2 rotates positively at 300 rpm
Extended Functions
13.4 Points to note

N05 G4 F1;
N10 COUPDEF(S2,S1,-1) ; Coupling factor -1:1
N11 COUPON(S2,S1) ; Activate coupling, the speed of following spindle S2
; results from the speed of the main spindle S1 and
; the coupling factor
N26 M2=3 S2=100 ; Programming of the speed difference,
; S2 is the following spindle
Application
Manufacturing operations with positioned leading spindle and rotating tools require exact
synchronism with the counter spindle which then functions like a following spindle. A turret
rotating about the following spindle allows parts to be machined with different tool types. The
following diagram shows an application in which the tool is positioned parallel to the main
spindle.
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Figure 13-5 Application on a single-slide turning machine with turret about Z axis
Requirements
Basic requirements for differential speed programming:
Synchronous spindle functionality is required.
The dynamic response of the following spindle must be at least as high as that of the
leading spindle. Otherwise, the system may suffer from reduced quality, for example, rigid
tapping without a compensating chuck G331/G332.
Extended Functions
13.4 Points to note
The differential speed must be programmed in the channel in which the following spindle
is also configured. The leading spindle can be programmed in a different channel.
The differential speed must be enabled for the following spindle by the PLC via IS
"Enable overlaid movement" (DB31, ... DBX26.4). If the enable signal has not been set,
alarm 16771 "Channel% Following axis% Overlaid movement not enabled" is output. This
alarm is cleared when IS "Enable overlaid movement" (DB31, ... DBX26.4) is set or the
coupling is terminated.
Note
The differential speed does not therefore affect the coupling process.
The following or leading spindle cannot change gear stages while a coupling is active.
Activate coupling with COUPONC

When the coupling is activated, the following spindle is accelerated, as before, to the leading
spindle speed through application of the coupling factor. If the following spindle is already
rotating (M3, M4) when the coupling is activated, it continues with this motion after coupling.
Deactivate coupling
If the coupling is deactivated, the following spindle continues to rotate at the speed
corresponding to the sum of both speed components. The spindle behaves as if it had been
programmed with the speed and direction transferred from the other spindle. When
deactivating, there are no differences to the previous behavior.
Differential speed
A differential speed results from the renewed programming of the following spindle (in the
example, S2=...) or M2=3, M2=4 in speed control mode during an active synchronous
spindle coupling or by adopting the speed of the following spindle for COUONC.
Condition:
Speed S... must also be re-programmed with direction of rotation M3 or M4. Otherwise alarm
16111 "Channel% Block% Spindle% No speed programmed" is displayed.
Read offsets of following spindle

The current offset always changes when a differential speed is programmed. The current
offset can be read at the setpoint end with $AA_COUP_OFFS[Sn] and at the actual value
end with $VA_COUP_OFFS[Sn].
The last offset programmed returns the variable $P_COUP_OFFS[Sn].
Extended Functions
13.4 Points to note
Display differential speed

The programmed difference component is displayed as the speed setpoint for the
programmed differential speed (in our example, corresponds to 100 rpm).
The actual speed refers to the motor speed. In the example, the actual speed is 500 rev/min
* (-1) + 100 rpm = -400 rev/min.
IS NCK to PLC
Following spindle in speed-controlled operation
The IS "Spindle in setpoint range" (DB31, ... DBX83.5) is set for the following spindle by the
NCK if the programmed speed difference (see previous example, N26 with M2=3 S2=100) is
reached. If a differential speed is programmed and not enabled by the PLC, this VDI
interface signal is not set.
Even if a differential speed has been programmed, the following spindle remains under
position control if this is required by the coupling.
Note
The axial VDI interface signal NCK PLC IS "Superimposed motion" (DB31, ... DBX98.4) is
set when the differential speed programming creates setpoints in addition to the coupling
setpoints.
Actual direction of rotation clockwise (DB31, ... DBX83.7)

IS "Actual direction of rotation clockwise" (DB31, ... DBX83.7) refers to the resulting motor
direction.
IS PLC to NCK
Influence on following spindle via PLC interface
The effect of the axial VDI interface signals on the following spindle with differential speed in
speed control mode is described below.
Delete distance to go / Spindle Reset (DB31, ... DBX2.2)

The programmed differential speed and direction can be terminated by IS "Delete distance-
to-go / Spindle Reset" (DB31, ... DBX2.2). To delete the programmed speed only, it is
possible to set IS "Delete S value" (DB31, ... DBX16.7).
Resynchronize spindle 1/2 (DB31, ... DBX16.4 and 16.5)

The IS "Resynchronize spindle 1/2" (DB31, ... DBX16.4/16.5) are not locked. Any positional
offset is not compensated automatically by the coupling.
Extended Functions
13.4 Points to note
Invert M3/M4 (DB31, ... DBX17.6)

IS "Invert M3/M4" (DB31, ... DBX17.6) only inverts the additional programmed speed
component for the following spindle.
The motion component generated by the synchronous spindle coupling remains unaffected.
Spindle override (DB31, ... DBB19)

The "Spindle override" VDI interface (DB31, ... DBB19) only affects the additional
programmed speed component for the following spindle. If the spindle override switch is
transferred to all axial inputs, then any change in the spindle override value is applied doubly
to the following spindle:
once indirectly by a change in speed for the leading spindle and
once in the programmed component of the following spindle.
The offset value can be adjusted accordingly in the PLC program.
Coupling deselection
If the coupling is deactivated, the following spindle continues to rotate at the speed
corresponding to the sum of both speed components. The motion transition upon coupling
deselection is at continuous speed.
With COUPOF, the spindle behaves as if it had been programmed with the speed and direction
transferred from the other spindle. In the example, this would be M4 S400.
When COUPOFS is programmed, the following spindle is decelerated to standstill from the
current speed.
Activate additional functions

The following spindle can also be a master spindle. In this case, it is capable of additional
functions.
Rotational feedrate with G95, G96 and G97. With G96 S2=... the "constant cutting speed"
can be activated for the following spindle.
The speed dependent on the position of the transverse axis is the setpoint speed for the
speed interpolator of spindle 2 and is therefore included in the total speed of S2.
Rigid tapping without compensating chuck with G331, G332.
Extended Functions
13.4 Points to note
13.4.5 Behavior of synchronism signals during synchronism correction
Effect of synchronism correction

New synchronism signals are produced by comparing the actual values with the corrected
setpoints. Once a correction process has been undertaken, the synchronism signals should
be present again.
13.4.6 Delete synchronism correction and NC reset

Variable $AA_COUP_CORR[Sn] returns the value zero for different situations in which the
synchronism correct is deleted:
Once a synchronized spindle coupling has been activated for the following in question
with COUPON(..)/COUPONC(..), an existing synchronism correction is adopted in the setpoint
position.
A synchronism correction active during NC reset but not at the parts program end is
adopted in the setpoint position. This does not affect the synchronism signals.
At M30, an existing synchronism correction is retained
At the user end, the correction value can also be deleted at any early point by describing
the variable $AA_COUP_CORR with the value zero. The synchronism correction is
removed immediately and using a ramp with reduced acceleration rate if larger values are
involved.
13.4.7 Special points regarding start-up of a synchronous spindle coupling
Spindle start-up
The leading and following spindles must be started up initially like a normal spindle. The
appropriate procedure is described in:
References:
CNC Commissioning Manual: NCK, PLC, Drive
Requirements
The following parameters must then be set for the synchronous spindle pair:
The machine numbers for the leading and following spindles
(for permanently configured coupling with channel-specific machine data MD21300
$MC_COUPLE_AXIS_1[n])
Extended Functions
13.4 Points to note
The required coupling mode (setpoint, actual value or speed coupling)

(for permanently configured coupling with channel-specific machine data
MD21310 $MC_COUPLING_MODE_1[n])
The gear stage(s) of FS and LS for synchronous operation
The following coupling properties are still applicable for permanently configured
synchronous spindle coupling:
Block change response in synchronous spindle operation:
MD21320 $MC_COUPLE_BLOCK_CHANGE_CTRL_1
Coupling cancellation response:
MD21330 $MC_COUPLE_RESET_MODE_1
Write-protection for coupling parameters:
MD21340 $MC_COUPLE_IS_WRITE_PROT_1
Transformation parameters for synchronous spindle coupling:
SD42300 $SC_COUPLE_RATIO_1[n]
Command behavior of FS and LS for setpoint coupling

In order to obtain the best possible synchronism in setpoint couplings, the FS and LS must
have the same dynamic response as the response to setpoint changes. The axial control
loops (position, speed and current controllers) should each be set to the optimum value so
that variances can be eliminated as quickly and efficiently as possible.
The dynamic response adaptation function in the setpoint branch is provided to adapt
different axis dynamic responses without loss of control quality (see also Section "K3:
Compensations (Page 223)"). The following control parameters must each be set optimally
for the FS and LS:
KV factor (MD32200 $MA_POSCTRL_GAIN)
Feedforward control parameters
MD32620 $MA_FFW_MODE
MD32610 $MA_VELO_FFW_WEIGHT
MD32650 $MA_AX_INERTIA
MD32800 $MA_EQUIV_CURRCTRL_TIME
MD32810 $MA_EQUIV_SPEEDCTRL_TIME
Behavior during loss of synchronism:
Axis-specific MD32620 $MA_FFW_MODE
We recommend setting the feedforward control mode of the following axis to speed
feedforward control with Tt symmetrization MD32620 = 3.
Extended Functions
13.4 Points to note
This feedforward control mode can be further optimized for a more secure symmetrization
process by changing the axis-specific machine data:

MD32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant speed control loop for
feedforward control
MD37200 COUPLE_POS_TOL_COURSE Threshold value for "Coarse synchronism"
MD37210 COUPLE_POS_TOL_FINE Threshold value for "Fine synchronism"
MD37220 COUPLE_VELO_TOL_COURSE Velocity tolerance 'coarse'
MD37220 COUPLE_VELO_TOL_FINE Velocity tolerance 'fine'
In such cases, higher threshold values for the synchronism signals and larger position and/or
speed tolerances result in more stable results.
Dynamic response adaptation

To obtain a good control behavior, FS and LS must have the same dynamic response. The
following error for FS and LS must be equal at any given speed. For dynamically different
spindles, a matching via the dynamic response adaptation can be achieved in the setpoint
branch. The difference of the equivalent time constants between the dynamic "weakest"
spindle to the associated other spindle must be entered as time constant of the dynamic
response adaptation.
Example
When the speed feedforward control is active, the dynamic response is primarily determined
by the equivalent time constant of the "slowest" speed control loop.
Equivalent time constant LS: MD32810 $MA_EQUIV_SPEEDCTRL_TIME[<LS>] = 5 ms
Equivalent time constant FS: MD32810 $MA_EQUIV_SPEEDCTRL_TIME[<FS>] = 3 ms
Time constant of dynamic response adaptation for FS: MD32910
$MA_DYN_MATCH_TIME[<FS>] = 5 ms - 3 ms = 2 ms
Activation of the dynamic response adaptation for FS: MD32900
$MA_DYN_MATCH_ENABLE[<FS>] = 1
The following error for FS and LS is identical for correctly set dynamic response adaptation:
Operating area "Diagnostics" > "Service axes"
For the optimization, it may be necessary to adjust servo gain factors or feedforward control
parameters slightly.
Position control parameter sets

In the case of spindles, each gear stage is assigned a position-control parameter set. These
parameter sets can be used to adapt the dynamic response for LS and FS in synchronous
operation. This requires that a different gear stage is used for speed and positioning
operation and synchronous operation. The associated gear stage must be switched before
activating the associated operating mode.
Extended Functions
13.4 Points to note
Control parameters
The following control parameters must be set identically for the FS and LS:
MD33000 $MA_FIPO_TYPE (fine interpolator type)
MD32400 $MA_AX_JERK_ENABLE (axial jerk limitation)
MD32402 $MA_AX_JERK_MODE (filter type for axial jerk limitation)
MD32410 $MA_AX_JERK_TIME (time constant for the axial jerk filter)
MD32412 $MA_AX_JERK_FREQ (blocking frequency of the axial jerk filter)
MD32414 $MA_AX_JERK_DAMP (damping of the axial jerk filter)
MD32420 $MA_JOG_AND_POS_JERK_ENABLE (release jerk limitation)
MD32430 $MA_JOG_AND_POS_MAX_JERK (axial jerk)
FS: Automatic parameterization of the control parameters

The control parameters of the following spindle can be set as follows using this machine
data:
MD30455 $MA_MISC_FUNCTION_MASK
Bit 5=0: Synchronous spindle coupling, following spindle:
Position control, feedforward control and parameter block are set for the following spindle.
Bit 5=1: Synchronous spindle coupling:
The control parameters of the following spindle are set as in an uncoupled scenario.
References:
Function Manual Basic Functions; Velocities, Setpoint / Actual Value Systems, Closed-Loop
Control (G2)
Automatic transfer of the LS parameters for synchronous operation

For the automatic dynamic response adaptation for FS and LS, for synchronous operation,
the parameter values for the position control, feedforward control and parameter records of
the FS can be transferred from the LS:
MD30455 $MA_MISC_FUNCTION_MASK, Bit 5
Separate dynamic response for spindle and axis operations

In spindle and axis operations, dynamic programming FA, OVRA, ACC and VELOLIMA can
be set separately from one another with the following MD:
MD30455 $MA_MISK_FUNCTION_MASK Bit 6=0
Assignment is undertaken by the programmed axis or spindle name. For example, in spindle
operation, VELOLIMA[S1]=50 therefore only reduces the maximum speed to 50% and in
axis operation, VELOLIMA[C]=50 only reduces the maximum speed to 50%.
Extended Functions
13.4 Points to note
If, for example, VELOLIMA[S1]=50 and VELOLIMA[C]=50 are to have the same effect as
before with this machine data, the programming of FA, OVRA, ACC and VELOLIM have an
effect regardless of the programmed names:
MD30455 $MA_MISK_FUNCTION_MASK Bit 6=1
Knee-shaped acceleration characteristic

For the leading spindle, the effect of a knee-shaped acceleration characteristic on the
following spindle is identified by the following axis-specific machine data:
MD35220 $MA_ACCEL_REDUCTION_SPEED_POINT (speed for reduced acceleration)
and
MD35230 $MA_ACCEL_REDUCTION_FACTOR (reduced acceleration).
If MD35242 $MA_ACCEL_REDUCTION_TYPE is present, it is also used to configure the
type of acceleration reduction. Otherwise a hyperbolic drop in acceleration is assumed.
If the dynamic response of a following spindle is lower than that of the leading spindle when
the coupling factor is taken into account, the leading spindle dynamic response is reduced to
the required level while the coupling is active.
The acceleration should be constant over the entire speed range for the following spindle.
However, if a knee-shaped acceleration characteristic is also stored in the above-mentioned
machine data for the following spindle, this is only taken into account when the spindles are
coupled in. The setpoints of the following spindle are applied for the specified knee-shaped
acceleration characteristic.
References:
Function Manual, Basic Functions; Acceleration (B2),
Section: Knee-shaped acceleration characteristic
Actual value coupling

In an actual value coupling (AV), the drive for the FS must be considerably more dynamic
than the leading spindle drive. The individual drives in an actual value coupling are also set
optimally according to their dynamic response.
An actual value coupling should only be used in exceptional cases.
Speed coupling
The velocity coupling (VV) corresponds internally to a setpoint coupling (DV), but with lower
dynamic requirements of the FS and LS. A position control servo loop is not required for the
FS and/or LS. Measuring systems are not required.
Extended Functions
13.4 Points to note
Threshold values for coarse/fine synchronism

After controller optimization and feedforward control setting, the threshold values for coarse
and fine synchronism must be entered for the FS.
Threshold value for "Coarse synchronism"
axis-specific MD7200: AV, DV: COUPLE_POS_TOL_COARSE
MD37220: VV: COUPLE_VELO_TOL_COARSE
Threshold value for "Fine synchronism"
axis-specific MD37210: AV, DV: COUPLE_POS_TOL_FINE
MD37230: VV: COUPLE_VELO_TOL_FINE
The values of the FS must be calculated according to the accuracy requirements of the
machine manufacturer, and the PLC interface must be checked via the service display.
Angular offset LS/FS

If there must be a defined angular offset between the FS and LS, e.g. when synchronous
operation is activated, the "zero degree positions" of the FS and LS must be mutually
adapted. This can be done with the following machine data:
MD34100 $MA_REFP_SET_POS
MD34080 $MA_REFP_MOVE_DIST
MD34090 $MA_REFP_ MOVE_DIST_CORR
References:
Service display for FS

In the "Diagnostics" operating area, when commissioning in the synchronous mode, the
following values are displayed for the following spindle:
Actual deviation between setpoints of FS and LS
Value displayed: Position offset in relation to leading spindle (setpoint)
(value corresponds to angular offset between FS and LS that can be read with axis
variable $AA_COUP_OFFS in the part program)
Actual deviation between actual values of FS and LS
Value displayed: Position offset in relation to leading spindle (actual value)
References:
Operating Manual
Extended Functions
13.5 Boundary conditions
13.5 Boundary conditions
Availability of the "synchronous spindle" function

The function is an option ("synchronous spindle/multi-edge turning" or the corresponding
optional version of the generic coupling), which must be assigned to the hardware via the
license management.
Note
Information on the different versions of the generic coupling, refer to:
References:
Function Manual Special Functions; Coupled Axes (M3)
13.6 Examples
Programming example

; Leading spindle = master spindle = spindle 1
; Following spindle = spindle 2
N05 M3 S3000 M2=4 S2=500 ; Master spindle rotates at 3000 rpm
; FS: 500 rpm
N10 COUPDEF (S2, S1, 1, 1, "No", ; Def. of coupling, can also
"Dv")
; be configured
N70 SPCON ; Include leading spindle in the position
control
; (setpoint value coupling).
N75 SPCON(2) ; Bring following spindle into closed-loop
position control
N80 COUPON (S2, S1, 45) ; On-the-fly coupling to offset position = 45
degrees
N200 FA [S2] = 100 ; Positioning speed = 100 degrees/min
N205 SPOS[2] = IC(-90) ; Traverse with 90 overlay in negative
direction
N210 WAITC(S2, "Fine") ; Wait for "fine" synchronism
N212 G1 X.., Y.. F... ; Machining
N215 SPOS[2] = IC(180) ; Traverse with 180 overlay in positive
direction
N220 G4 S50 ; Dwell time = 50 revolutions
; of master spindle
Extended Functions
13.7 Data lists

N225 FA [S2] = 0 ; Activate configured velocity (MD)
N230 SPOS[2] = IC (-7200) ; 20 rev. with configured velocity
; in neg. direction
N350 COUPOF (S2, S1) ; On-the-fly decoupling, S = S2 = 3000
N355 SPOSA[2] = 0 ; Stop FS at zero degrees
N360 G0 X0 Y0
N365 WAITS(2) ; Wait for spindle 2
N370 M5 ; Stop FS
N375 M30
13.7 Data lists
13.7.1 Machine data
13.7.1.1 NC-specific machine data

10000 AXCONF_MACHAX_NAME_TAB Machine axis name

20070 AXCONF_MACHAX_USED Machine axis number valid in channel
21300 COUPLE_AXIS_1 Definition of synchronous spindle pair
21310 COUPLING_MODE_1 Type of coupling in synchronous spindle mode
21320 COUPLE_BLOCK_CHANGE_CTRL_1 Block change behavior in synchronous spindle
operation
21330 COUPLE_RESET_MODE_1 Coupling abort behavior
21340 COUPLE_IS_WRITE_PROT_1 Coupling parameters are write-protected
Extended Functions
13.7 Data lists

30455 MISK_FUNCTION_MASK Axis functions
30550 AXCONF_ASSIGN_MASTER_CHAN Reset position of channel for axis change
32200 POSCTRL_GAIN Servo gain factor
32400 AX_JERK_ENABLE Axial jerk limitation
32410 AX_JERK_TIME Time constant for axial jerk filter
32420 JOG_AND_POS_JERK_ENABLE Initial setting for axial jerk limitation
32430 JOG_AND_POS_MAX_JERK Axial jerk
32610 VELO_FFW_WEIGHT Feedforward control factor for speed feedforward
control
32620 FFW_MODE Feedforward control mode
32650 AX_INERTIA Moment of inertia for torque feedforward control
32800 EQUIV_CURRCTRL_TIME Equivalent time constant current control loop for
feedforward control
32810 EQUIV_SPEEDCTRL_TIME Equivalent time constant speed control loop for
feedforward control
34080 REFP_MOVE_DIST Reference point approach distance
34090 REFP_MOVE_DIST_CORR Reference point offset
34100 REFP_SET_POS Reference point value
35000 SPIND_ASSIGN_TO_MACHAX Assignment of spindle to machine axis
37200 COUPLE_POS_TOL_COARSE Threshold value for "Coarse synchronism"
37210 COUPLE_POS_TOL_FINE Threshold value for "Fine synchronism"
37220 COUPLE_VELO_TOL_COARSE Speed tolerance "coarse" between leading and
following spindles
37230 COUPLE_VELO_TOL_FINE Speed tolerance "fine" between leading and following
spindles
13.7.2 Setting data

42300 COUPLE_RATIO_1 Transmission parameters for synchronous spindle operation
Extended Functions
13.7 Data lists
13.7.3 Signals

NC Start DB21, ... .DBX7.1 DB3200.DBX7.1
NC Stop axes plus spindle DB21, ... .DBX7.4 DB3200.DBX7.4

Dry run feedrate selected DB21, ... .DBX24.6 DB1700.DBX0.6
Feedrate override selected for rapid traverse DB21, ... .DBX25.3 DB1700.DBX1.3

Axis/spindle disable DB31, ... .DBX1.3 DB380x.DBX1.3
Follow-up mode DB31, ... .DBX1.4 DB380x.DBX1.4
Position measuring system 1, position measuring system DB31, ... .DBX1.5/6 DB380x.DBX1.5/6
2
Controller enable DB31, ... .DBX2.1 DB380x.DBX2.1
Distance-to-go/Spindle RESET DB31, ... .DBX2.2 DB380x.DBX2.2
Spindle stop/feed stop DB31, ... .DBX4.3 DB380x.DBX4.3
Traversing keys for JOG DB31, ... .DBX4.6/7 DB380x.DBX4.6/7
Re-synchronize spindle 1, re-synchronize spindle 2 DB31, ... .DBX16.4/5 DB380x.DBX2000.4/5
Delete S value DB31, ... .DBX16.7 DB380x.DBX2000.7
Feedrate override valid DB31, ... .DBX17.0 DB380x.DBX2001.0
Invert M3/M4 DB31, ... .DBX17.6 DB380x.DBX2001.6
Spindle override DB31, ... .DBB19 DB380x.DBB2003
Re-synchronizing DB31, ... .DBX31.4 -
Disable synchronization DB31, ... .DBX31.5 -
Extended Functions
13.7 Data lists

Referenced/synchronized 1, referenced/synchronized 2 DB31, ... .DBX60.4/5 DB390x.DBX0.4/5
Synchronous mode DB31, ... .DBX84.4 DB390x.DBX2002.4
Synchronism fine DB31, ... .DBX98.0 -
Synchronism coarse DB31, ... .DBX98.1 -
Actual value coupling DB31, ... .DBX98.2 -
Superimposed motion DB31, ... .DBX98.4 DB390x.DBX5002.4
Leading spindle LS/LA active DB31, ... .DBX99.0 -
Following spindle FS/FA active DB31, ... .DBX99.1 -

$P_COUP_OFFS[following spindle] Programmed offset of the synchronous spindle
$AA_COUP_OFFS[following spindle] Position offset for synchronous spindle (setpoint)
$VA_COUP_OFFS[following spindle] Position offset for synchronous spindle (actual value)
For a more detailed description of system variables, see:

References:
List Manual System Variables
Extended Functions
13.7 Data lists
Extended Functions
S7: Memory configuration 14
Memory types
To store and manage data, the NC requires a static memory and a dynamic memory:
Static NC memory
In the static NC memory, the program data (part programs, cycles, etc.) and the current
system and user data (tool management, global user data, etc.) is saved to persistent
memory.
Dynamic NC memory
In the dynamic NC memory the data is saved to non-persistent memory. The data here
concerns information generated by the NC that is only required for a limited time (e.g.,
macros, local user data, interpolation buffer, etc.).
Memory organization
The memory areas of the individual data groups in the static and dynamic NC memories
have defined sizes, which are fixed when the memory is configured.
This type of memory organization ensures the deterministic behavior of the control: The
reserved memory area is guaranteed throughout part program processing.
Memory configuration
When booted for the first time, the system enters default values in all other memory-
configuration machine data. This configuration is adequate in most cases. However, the
machine manufacturer/user can make changes at any time (Reconfiguration).
Extended Functions
S7: Memory configuration
14.2 Memory organization
14.2.1 Active and passive file system

The static NC memory contains an active and passive file system.
Active file system

The active file system contains system data used to parameterize the NCK:
Machine data
Setting data
Option data
Global user data (GUD)
Tool-offset/magazine data
Protection zones
R parameters
Work offsets/FRAME
Sag compensations
Quadrant error compensation
Leadscrew error compensation
This data represents the current work data of the NCK.
The user's view of the active file system is data-oriented.
Passive file system

The passive file system contains all files loaded onto the NCK:
Main programs
Subprograms
Global-user-data and macro definition files (*.DEF)
Standard cycles
User cycles
Workpieces
Comments
The user's view of the passive file system is file-oriented.
Extended Functions
14.2.2 Reconfiguration
Reconfiguration
NOTICE
Data loss
A reconfiguration of the static NC memory results in a loss of data on the active and
passive file system. Before activating the modified memory configuration, you must must
first save the data by creating a series machine start-up file.
The following actions result in the reconfiguration of the static and/or dynamic NC memory:
Changing the settings of memory-configuration machine data:
MD... $..._MM_...
Changing the number of channels
Extended Functions
14.3 Configuration of the static user memory
14.3.1 Division of the static NC memory

The figure below shows the division of the static NC memory for SINUMERIK 840D sl:
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Extended Functions
Static user memory

The static NC memory is used jointly by the system and by the user.
The area available to the user is defined as the static user memory. It contains the data from
the active and passive file system.
Static-user-memory size
The size of the static user memory is defined in machine data:
MD18230 $MN_MM_USER_MEM_BUFFERED
Memory space for passive file system

The memory space for the passive file system has a defined size and is divided into the
following partitions:
Partition Storage of:

S (Siemens = Control manufacturer) Files from the _N_CST_DIR directory (Siemens cycles)
M (Manufacturer = Machine manufacturer) Files from the _N_CMA_DIR directory (Machine-
manufacturer cycles)
U (User = End customer) Files from the _N_CUS_DIR directory (User cycles, part
programs, workpieces)
E (EXT = External) External files (e.g., part programs from USB FlashDrive
or CD).
Note:
To avoid naming conflicts with internal part programs,
part programs installed from external data carriers are
stored in a separate directory (_N_EXT_DIR).
Advantage of separation:
This separation into different partitions ensures that a series machine start-up file can be
reloaded onto the NCK even in the event of an NCK software or cycle package upgrade (that
has expanded the area of Siemens cycles).
Size of the partitions:
The size of partitions S and E are preset and cannot be modified.
You can divide the remaining memory available for the passive file system into the partitions
U and M as you see fit. The settings are made with machine data:
MD18352 $MN_MM_U_FILE_MEM_SIZE
(end-user memory for part programs/cycles/files)
MD18353 $MN_MM_M_FILE_MEM_SIZE
(memory size for cycles/files of the machine manufacturer)
Extended Functions
The maximum adjustable values depend on:

The system and thus the memory space available (including an optional memory
expansion)
from the defined maximum values, see also:
References:
Detailed machine-data description
Memory space for active file system

The memory space for the active file system is divided into various data areas (tool
management, global user data, etc.), which can be defined individually using machine data.
The memory still available is shown in machine data:
MD18060 $MN_INFO_FREE_MEM_STATIC
(free-static-memory display data)
You can expand the sizes of the individual memory areas for the active file system with the
relevant machine data until the available memory has been used.
Note
The memory required to expand the memory areas is displayed in the "Startup" area of the
user interface. This information enables the system startup engineer to estimate the actual
memory requirements for the planned expansion.
Memory expansion (option)

The machine manufacturer can also purchase additional static user memory as an option.
You can use the additional memory space as required to expand partitions U and M or to
expand the memory area of the active file system.
Extended Functions
14.3.2 Commissioning
Procedure
1. Load standard machine data.
2. Preset machine data:
MD18230 $MN_MM_USER_MEM_BUFFERED
with a high value (> default memory available + optional additional memory).
3. Reset the NCK.
Alarm 6030 "User memory limit adjusted" is triggered and the maximum memory
available for the user is entered in MD18230 (including optional memory expansion).
Default values are entered in all other memory-configuration machine data.
4. Set the sizes of partitions U and M in machine data:
MD18352 $MN_MM_U_FILE_MEM_SIZE
(end-user memory for part programs/cycles/files)
MD18353 $MN_MM_M_FILE_MEM_SIZE
(memory size for cycles/files of the machine manufacturer)
5. Activate the number of required channels and axes.
6. You can adjust the default memory division by increasing/decreasing individual memory
areas of the active file system (tool management, global user data, etc.) for each user.
The static user memory still available is displayed in machine data:
MD18060 $MN_INFO_FREE_MEM_STATIC
(free-static-memory display data)
Set machine data (see Section "Data lists (Page 764)").
References:
7. Reset the NCK.
The memory is set up again.
Extended Functions
14.4 Configuration of the dynamic user memory
14.4.1 Division of the dynamic NC memory

The figure below shows the division of the dynamic NC memory:
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Figure 14-2 Dynamic NC memory
Extended Functions
Dynamic user memory

The dynamic NC memory is used jointly by the system and by the user. The area available
to the user is defined as the dynamic user memory.
Dynamic-user-memory size
The size of the dynamic user memory is set in machine data:
MD18210 $MN_MM_USER_MEM_DYNAMIC
Changes are not usually required as an appropriate value is automatically set during the
reconfiguration.
Dynamic user memory still available

The dynamic memory still available is shown in machine data:
MD18050 $MN_INFO_FREE_MEM_DYNAMIC
(free-dynamic-memory display data)
The content of this machine data indicates how much memory is available to expand the
user data areas (local user data, IPO buffer, etc.) for each channel.
14.4.2 Commissioning
You can adjust the default memory division by increasing/decreasing individual memory
areas for each user.
Procedure
1. The dynamic user memory still available is displayed in machine data:
MD18050 $MN_INFO_FREE_MEM_DYNAMIC
(free-dynamic-memory display data)
2. Set machine data (see Section "Data lists (Page 764)").
References:
3. Reset the NCK.
The memory is set up again.
Extended Functions
14.5 Data lists
14.5 Data lists
14.5.1 Machine data

10134 MM_NUM_MMC_UNITS Number of simultaneous HMI communication partners
10850 MM_EXTERN_MAXNUM_OEM_GCODES Maximum number of OEM-G codes
10880 MM_EXTERN_CNC_SYSTEM Definition of the control system to be adapted
10881 MM_EXTERN_GCODE_SYSTEM ISO_3 Mode: GCodeSystem
18050 INFO_FREE_MEM_DYNAMIC Free-dynamic-memory display data
18060 INFO_FREE_MEM_STATIC Free-static-memory display data
18070 INFO_FREE_MEM_DPR Display data for free memory in
dual-port RAM
18072 INFO_FREE_MEM_CC_MD Displays memory available in the CC-MD memory
18078 MM_MAX_NUM_OF_HIERARCHIES Maximum number of definable magazine-location-
type hierarchies
18079 MM_MAX_HIERARCHY_ENTRIES Maximum permissible number of entries in a
magazine-location-type hierarchy
18080 MM_TOOL_MANAGEMENT_MASK Mask for reserving memory for tool management
18082 MM_NUM_TOOL Number of tools managed by NCK
18084 MM_NUM_MAGAZINE Number of magazines managed by NCK
18086 MM_NUM_MAGAZINE_LOCATION Number of magazine locations
18088 MM_NUM_TOOL_CARRIER Maximum number of definable toolholders
18090 MM_NUM_CC_MAGAZINE_PARAM Compile-cycle tool management:
quantity of magazine data
18092 MM_NUM_CC_MAGLOC_PARAM Compile-cycle tool management:
quantity of magazine-location data
18094 MM_NUM_CC_TDA_PARAM Compile-cycle tool management: quantity of TDA data
18096 MM_NUM_CC_TOA_PARAM Compile-cycle tool management: quantity of TOA data
18098 MM_NUM_CC_MON_PARAM Compile-cycle tool management:
quantity of monitor data
18100 MM_NUM_CUTTING_EDGES_IN_TOA Number of tool offsets in NCK
18102 MM_TYPE_OF_CUTTING_EDGE Type of D-number programming
18104 MM_NUM_TOOL_ADAPTER Tool adapter in TO area
18105 MM_MAX_CUTTING_EDGE_NO Maximum value of D number
18106 MM_MAX_CUTTING_EDGE_PERTOOL Maximum number of D numbers per tool
18108 MM_NUM_SUMCORR Additive offsets in the TO area
Extended Functions
14.5 Data lists

18110 MM_MAX_SUMCORR_PER_CUTTEDGE Maximum number of sum offsets per cutting edge
18112 MM_KIND_OF_SUMCORR Properties of additive offsets in the TO area
18114 MM_ENABLE_TOOL_ORIENT Assign orientation to cutting edges
18116 MM_NUM_TOOL_ENV Number of tool environments in TO area
18118 MM_NUM_GUD_MODULES Number of GUD modules
18120 MM_NUM_GUD_NAMES_NCK Number of global user variables
18130 MM_NUM_GUD_NAMES_CHAN Number of channel-specific user variables
18140 MM_NUM_GUD_NAMES_AXIS Number of axis-specific user variables
18150 MM_GUD_VALUES_MEM Memory space for global user variables
18160 MM_NUM_USER_MACROS Number of macros
18170 MM_NUM_MAX_FUNC_NAMES Number of miscellaneous functions
18180 MM_NUM_MAX_FUNC_PARAM Number of additional parameters
18190 MM_NUM_PROTECT_AREA_NCK Number of protection zones in NCK
18200 MM_NUM_CCS_MAGAZINE_PARAM Number of Siemens OEM magazine data
18201 MM_TYPE_CCS_MAGAZINE_PARAM Siemens OEM magazine data type
18202 MM_NUM_CCS_MAGLOC_PARAM Number of Siemens OEM magazine location data
18203 MM_TYPE_CCS_MAGLOC_PARAM Siemens OEM magazine location data type
18204 MM_NUM_CCS_TDA_PARAM Number of Siemens OEM tool data
18205 MM_TYPE_CCS_TDA_PARAM Siemens OEM tool data type
18206 MM_NUM_CCS_TOA_PARAM Number of Siemens OEM data per cutting edge
18207 MM_TYPE_CCS_TOA_PARAM Siemens OEM data type per cutting edge
18208 MM_NUM_CCS_MON_PARAM Number of Siemens OEM monitor data
18209 MM_TYPE_CCS_MON_PARAM Siemens OEM monitor data type
18210 MM_USER_MEM_DYNAMIC User memory in DRAM
18220 MM_USER_MEM_DPR User memory in dual-port RAM
18230 MM_USER_MEM_BUFFERED User memory in SRAM
18231 MM_USER_MEM_BUFFERED_TYPEOF Data-buffer technology
18232 MM_ACTFILESYS_LOG_FILE_MEM System: Log-file size
18238 MM_CC_MD_MEM_SIZE Machine-data compile cycles in SRAM
18240 MM_LUD_HASH_TABLE_SIZE Hash-table size for user variables
18242 MM_MAX_SIZE_OF_LUD_VALUE Maximum LUD-variable array size
18250 MM_CHAN_HASH_TABLE_SIZE Hash-table size for channel-specific data
18260 MM_NCK_HASH_TABLE_SIZE Hash-table size for global data
18270 MM_NUM_SUBDIR_PER_DIR Number of subdirectories
18280 MM_NUM_FILES_PER_DIR Number of files per directory
18290 MM_FILE_HASH_TABLE_SIZE Hash-table size for files in a directory
18300 MM_DIR_HASH_TABLE_SIZE Hash-table size for subdirectories
18310 MM_NUM_DIR_IN_FILESYSTEM Number of directories in passive file system
Extended Functions
14.5 Data lists

18320 MM_NUM_FILES_IN_FILESYSTEM Number of files in passive file system
18332 MM_FLASH_FILE_SYSTEM_SIZE Size of flash file system on PCNC
18342 MM_CEC_MAX_POINTS Maximum table size for sag compensation
18350 MM_USER_FILE_MEM_MINIMUM Minimum part-program memory
18352 MM_U_FILE_MEM_SIZE End-user memory for part programs/cycles/files
18353 MM_M_FILE_MEM_SIZE Memory size for cycles/files of the machine
manufacturer
18354 MM_S_FILE_MEM_SIZE Memory size for cycles/files of the NC manufacturer
18355 MM_T_FILE_MEM_SIZE Memory size for temporary files
18356 MM_E_FILE_MEM_SIZE Memory size for external files
18360 MM_EXT_PROG_BUFFER_SIZE FIFO buffer size for execution from external source
(DRAM)
18362 MM_EXT_PROG_NUM Number of program levels that can be processed
simultaneously from external
18370 MM_PROTOC_NUM_FILES Maximum number of log files
18371 MM_PROTOC_NUM_ETPD_STD_LIST Number of standard ETPD data lists
18372 MM_PROTOC_NUM_ETPD_OEM_LIST Number of ETPD OEM data lists
18373 MM_PROTOC_NUM_SERVO_DATA Number of servo data for log
18374 MM_PROTOC_FILE_BUFFER_SIZE Log-file buffer size
18375 MM_PROTOC_SESS_ENAB_USER User-enabled for sessions
18390 MM_COM_COMPRESS_METHOD Supported compression method
18400 MM_NUM_CURVE_TABS Number of curve tables (SRAM)
18402 MM_NUM_CURVE_SEGMENTS Number of curve segments (SRAM)
18403 MM_NUM_CURVE_SEG_LIN Number of linear curve segments (SRAM)
18404 MM_NUM_CURVE_POLYNOMS Number of curve table polynomials (SRAM)
18406 MM_NUM_CURVE_TABS_DRAM Number of curve tables (DRAM)
18408 MM_NUM_CURVE_SEGMENTS_DRAM Number of curve segments (DRAM)
18409 MM_NUM_CURVE_SEG_LIN_DRAM Number of linear curve segments (DRAM)
18410 MM_NUM_CURVE_POLYNOMS_DRAM Number of curve table polynomials (DRAM)
18450 MM_NUM_CP_MODULES Maximum number of CP modules
18452 MM_NUM_CP_MODUL_LEAD Maximum number of leading values per CP coupling
module
18500 MM_EXTCOM_TASK_STACK_SIZE Stack size of external communication task (DRAM)
18502 MM_COM_TASK_STACK_SIZE Stack size in Kbytes of communication task (DRAM)
18510 MM_SERVO_TASK_STACK_SIZE Stack size of servo task (DRAM)
18512 MM_IPO_TASK_STACK_SIZE Stack size of IPO task (DRAM)
18520 MM_DRIVE_TASK_STACK_SIZE Stack size of drive task (DRAM)
18540 MM_PLC_TASK_STACK_SIZE Stack size of PLC task (DRAM)
18600 MM_FRAME_FINE_TRANS Fine offset for FRAME (SRAM)
18601 MM_NUM_GLOBAL_USER_FRAMES Number of globally predefined user frames (SRAM)
Extended Functions
14.5 Data lists

18602 MM_NUM_GLOBAL_BASE_FRAMES Number of global basic frames (SRAM)
18660 MM_NUM_SYNACT_GUD_REAL Number of configurable real-type GUD variables
18661 MM_NUM_SYNACT_GUD_INT Number of configurable integer-type GUD variables
18662 MM_NUM_SYNACT_GUD_BOOL Number of configurable Boolean-type GUD variables
18663 MM_NUM_SYNACT_GUD_AXIS Number of configurable axis-type GUD variables
18664 MM_NUM_SYNACT_GUD_CHAR Configurable char-type GUD variable
18665 MM_NUM_SYNACT_GUD_STRING Configurable STRING-type GUD variable
18700 MM_SIZEOF_LINKVAR_DATA Size of the NCU link variable memory
18710 MM_NUM_AN_TIMER Number of global time variables for synchronized
actions
18720 MM_SERVO_FIFO_SIZE Setpoint for buffer size between IPO and closed-loop
position control
18780 MM_NCU_LINK_MASK Activation of NCU link communication
18781 NCU_LINK_CONNECTIONS Number of internal link connections
18782 MM_LINK_NUM_OF_MODULES Number of NCU link modules
18790 MM_MAX_TRACE_LINK_POINTS Size of trace data buffer for NCU link
18792 MM_TRACE_LINK_DATA_FUNCTION Specifies the contents of NCU link files
18794 MM_TRACE_VDI_SIGNAL Trace specification of VDI signals
18800 MM_EXTERN_LANGUAGE Activation of external NC languages
18860 MM_MAINTENANCE_MON Activate recording of maintenance data
18870 MM_MAXNUM_KIN_CHAINS Maximum number of trains
18880 MM_MAXNUM_KIN_CHAIN_ELEM Maximum number of train elements
18890 MM_MAXNUM_3D_PROT_AREAS Maximum number of elements in 3D protection zones
18892 MM_MAXNUM_3D_PROT_AREA_ELEM Maximum number of protection-zone elements
18894 MM_MAXNUM_3D_PROT_GROUPS Maximum number of protection-zone groups
18896 MM_MAXNUM_3D_COLLISION Maximum number of temporary memory locations for
collision check

20096 T_M_ADDRESS_EXIT_SPINO Spindle number as address extension
27900 REORG_LOG_LIMIT Percentage of IPO buffer for log-file enable
28000 MM_REORG_LOG_FILE_MEM Memory size for REORG
28010 MM_NUM_REORG_LUD_MODULES Number of modules for local user variables with
REORG
28020 MM_NUM_LUD_NAMES_TOTAL Number of local user variables
28040 MM_LUD_VALUES_MEM Memory size for local user variables
28050 MM_NUM_R_PARAM Number of channel-specific R parameters
Extended Functions
14.5 Data lists

28060 MM_IPO_BUFFER_SIZE Number of NC blocks in the IPO buffer
28070 MM_NUM_BLOCKS_IN_PREP Number of blocks for block preparation
28080 MM_NUM_USER_FRAMES Number of settable frames
28081 MM_NUM_BASE_FRAMES Number of basic frames (SRAM)
28082 MM_SYSTEM_FRAME_MASK System frames (SRAM)
28083 MM_SYSTEM_DATAFRAME_MASK System frames (SRAM)
28085 MM_LINK_TOA_UNIT Allocation of a TO unit to a channel
28090 MM_NUM_CC_BLOCK_ELEMENTS Number of block elements for compile cycles
28100 MM_NUM_CC_BLOCK_USER_MEM Size of block memory for compile cycles
28105 MM_NUM_CC_HEAP_MEM Heap memory in KB for compile cycle applications
(DRAM)
28150 MM_NUM_VDIVAR_ELEMENTS Number of elements for writing PLC variables
28160 MM_NUM_LINKVAR_ELEMENTS Number of write elements for the NCU link variables
28180 MM_MAX_TRACE_DATAPOINTS Size of trace data buffer
28200 MM_NUM_PROTECT_AREA_CHAN Number of modules for channel-specific protection
zones
28210 MM_NUM_PROTECT_AREA_ACTIVE Number of simultaneously active protection zones
28212 MM_NUM_PROTECT_AREA_CONTOUR Elements for active protection zones (DRAM)
28250 MM_NUM_SYNC_ELEMENTS Number of elements for expressions in synchronized
actions
28252 MM_NUM_FCTDEF_ELEMENTS Number of FCTDEF elements
28254 MM_NUM_AC_PARAM Dimension of $AC_PARAM.
28255 MM_BUFFERED_AC_PARAM $AC_PARAM[ ] is saved in SRAM.
28256 MM_NUM_AC_MARKER Dimension of $AC_MARKER
28257 MM_BUFFERED_AC_MARKER $AC_MARKER[ ] is saved in SRAM.
28258 MM_NUM_AC_TIMER Number of $AC_TIMER time variables (DRAM)
28274 MM_NUM_AC_SYSTEM_PARAM Number of $AC_SYSTEM_ PARAM for motion-
synchronous actions
28276 MM_NUM_AC_SYSTEM_MARKER Number of $AC_SYSTEM_ MARKER for motion-
synchronous actions
28290 MM_SHAPED_TOOLS_ENABLE Enable tool-radius compensation for contour tools
28300 MM_PROTOC_USER_ACTIVE Activate logging for a user
28301 MM_PROTOC_NUM_ETP_OEM_TYP Number of ETP OEM event types
28302 MM_PROTOC_NUM_ETP_STD_TYP Number of ETP standard event types
28400 MM_ABSBLOCK Activate block display with absolute values
28402 MM_ABSBLOCK_BUFFER_CONF Dimension size of upload buffer
28450 MM_TOOL_DATA_CHG_BUFF_SIZE Buffer for tool data changes (DRAM)
28500 MM_PREP_TASK_STACK_SIZE Stack size of preparatory task
28520 MM_MAX_AXISPOLY_PER_BLOCK Maximum number of axis polynomials per block
28530 MM_PATH_VELO_SEGMENTS Number of memory chips for limiting the tool-path
velocity
Extended Functions
14.5 Data lists

28535 MM_FEED_PROFILE_SEGMENTS Number of memory chips for feed profiles
28540 MM_ARCLENGTH_SEGMENTS Number of memory chips for displaying the arc length
function
28560 MM_SEARCH_RUN_RESTORE_MODE Restore data after a simulation
28580 MM_ORIPATH_CONFIG Setting for ORIPATH tool orientation trajectory
referred to path

38000 MM_ENC_COMP_MAX_POINTS Number of intermediate points with interpolatory
compensation
38010 MM_QEC_MAX_POINTS Number of values for quadrant-error compensation
Extended Functions
14.5 Data lists
Extended Functions
T1: Indexing axes 15
Indexing axes in machine tools

In certain applications, the axis is only required to approach specific grid points (e.g. location
numbers). It is necessary to approach the defined grid points, the indexing positions, both in
AUTOMATIC and set-up mode.
The relevant axes are called "indexing axes". The positions defined on the indexing axes are
known as "coded positions" or "indexing positions".
Applications
Indexing axes are used predominantly in connection with specific types of tool magazines
such as tool turrets, tool chain magazines or tool cartridge magazines. The coded positions
refer to the individual locations of the tools in the magazines. During a tool change, the
magazine is positioned at the location containing the tool to be loaded.
Display indexing
The following data can be queried via system variables:
The number of the current indexing position:
When the "exact stop fine" window of the indexing position is reached
When half the distance to the next indexing position is crossed
The programmed indexing position
15.2 Traversing of indexing axes

Indexing axes can be traversed:
Manually in the setting-up modes JOG and INC
from one part program with special instructions for coded positions
of PLC
Upon reaching the indexing position the following interface signal is given out to the PLC:
DB31, ... DBX76.6 (indexing axis in position)
Extended Functions
T1: Indexing axes
15.2.1 Traversing of indexing axes in the JOG mode

An indexing axis approaches the reference point in the same way as other axes. The
reference point does not have to coincide with an indexing position.
When reference point is reached:
DB31, ... DBX60.4 or 5 (referenced/synchronized 1 or 2) = 1
the indexing axis moves only to indexing positions in JOG mode during conventional and
incremental traversing.
Exception: No indexing positions are approached when traversing with the handwheel.
If the axis is not referenced (DB31, ... DBX60.4 or 5 = 0), the indexing positions are ignored
when traversing in JOG mode!
Note
Hirth indexing axes cannot be traversed in JOG mode before reference point approach.
Continuous traversal in JOG

Jog mode active:
SD41050 $SN_JOG_CONT_MODE_LEVELTRIGGRD = 1
Pressing a "+" or "-" traversing key causes the indexing axis to move in the same way as
with conventional JOG traversing. When the traversing key is released, the indexing axis
traverses to the next indexing position in the direction of traversing.
Continuous mode active:
SD41040 $SN_JOG_CONT_MODE_LEVELTRIGGRD = 0
Pressing the traversing key briefly (first rising signal edge) starts the traversing movement
of the indexing axis in the desired direction. Traversing continues when the traversing key
is released. When the traversing key is pressed again (second rising signal edge), the
indexing axis traverses to the next indexing position in the direction of traversing.
Indexing axes are generally traversed in JOG mode (standard setting). Continuous mode
plays a less important role.
If the operator changes the direction of traversing before the indexing position has been
reached, the indexing axis is positioned on the next indexing position in the direction of
traversing. The traversing movement must be started in the opposite direction.
For further information on continuous traversing in JOG or continuous mode (see Section
"H1: Manual and handwheel travel (Page 143)").
Extended Functions
T1: Indexing axes
Incremental traversal in JOG mode (INC)

Irrespective of the current increment setting (INC1, ... ,INCvar), the indexing axis always
traverses through one indexing position in the selected direction when a traversing key "+" or
"-" is pressed .
In jog mode, the traversing movement is interrupted when the traversing key is released. The
indexing position can be approached by pressing the traversing key again.
In continuous mode, the traversing movement is interrupted when the traversing key is
pressed again. The indexing axis is, in this case, not located on the indexing position.
Between indexing positions

If an indexing axis is situated between 2 indexing positions, then it approaches the next-
higher indexing position when the "+" traversing key is pressed in JOG-INC mode. Similarly,
pressing the "-" traversing key causes the next-lower indexing position to be approached.
Handwheel traversal
When the indexing axis is traversed by means of the handwheel in JOG mode, the indexing
positions are ignored. As the handwheel is turned, the indexing axis moves to any position
depending on the basic system in mm, inches or degrees.
If traversing of the indexing axis with the handwheel is to be interlocked, this can be handled
by the PLC user program.
Signal from PLC "Indexing axis in position"

During the traversing motion of the indexing axis in the JOG mode, the following NC/PLC
interface signal displays the reaching of the indexing position:
Requirement: The indexing axis is referenced (DB31, ... DBX60.4 or 5 = 1)
Alarms in JOG mode

If the indexing axis leaves the traversing range defined in the indexing position table when
traversing in JOG mode, alarm 20054 "wrong index for indexing axis in JOG" is output.
In JOG mode, the response of the axis / spindle also depends on the setting data:
SD41100 $SN_JOG_REV_IS_ACTIVE (revolutional feed rate for JOG active)
SD41100 Meaning
= 1 (active) The axis / spindle is always traversed with revolutional feed rate as a function of
the master spindle:
MD32050 $MA_JOG_REV_VELO (revolutional feed rate for JOG mode)
or
MD32040 $MA_JOG_REV_VELO_RAPID (revolutional feed rate for JOG with
rapid traverse override)
Extended Functions
T1: Indexing axes
SD41100 Meaning
= 0 (not active) The response of the axis / spindle depends on the setting data:
SD43300 $SA_ASSIGN_FEED_PER_REV_SOURCE(revolutional feed feed rate
for position axes / spindles)
The response of a geometry axis on which a frame acts is to rotate, depending
on the setting data:
SD42600 $SC_JOG_FEED_PER_REV_SOURCE
15.2.2 Traversing of indexing axes in the AUTOMATIC mode
Traversal to selected positions

An axis defined as an indexing axis can be made to approach any selected position from the
NC part program in AUTOMATIC mode. This includes positions between the defined
indexing positions.
These positions are programmed, in the usual way, in the unit of measurement (mm/inches
or degrees) for the axis. The general programming instructions used for this purpose (G90,
G91, AC, IC, etc.) are described in the Programming Manuals.
Traversal to "Coded positions"

Special instructions can also be used in the part program to traverse indexing axes to the
"coded positions":
Statement Effect
CAC Approach absolute coded position
CACP Approach absolute coded position in positive direction
CACN Approach absolute coded position in negative direction
CIC Approach incremental coded position
CDC Approach coded position along direct (shortest) path
With absolute positioning, the indexing position to be approached is programmed, and with
incremental positioning, the number of indexes to be traversed in the "+" or "-" direction is
programmed.
On rotary axes, the indexing position can be approached directly across the shortest path
(CDC) or with a defined direction of rotation (CACP, CACN).
Reaching the indexing position

If the "Exact stop fine" window is reached and the indexing axis is positioned on an indexing
position, the following NC/PLC interface signal is enabled regardless of how the indexing
position was reached.
Extended Functions
T1: Indexing axes
15.3 Parameterization of indexing axes
15.2.3 Traversing of indexing axes by PLC

Indexing axes can also be traversed from the PLC user program.
There are various methods:
Concurrent positioning axes
The indexing position to be approached can be specified by the PLC (see Section "P2:
Positioning axes (Page 599)").
Asynchronous subprograms (ASUBs)
References:
Function Manual, Basic Functions; Mode Group, Channel, Program Operation,
Reset Response (K1)
Definition of the indexing axis

An axis (linear or rotary axis) can be defined as indexing axis with the axial machine data:
MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB
Value Meaning
0 The axis is not declared as an indexing axis.
1 The axis is an indexing axis. The associated indexing positions are stored in the indexing
positions table 1.
2 The axis is an indexing axis. The associated indexing positions are stored in the indexing
positions table 2.
Indexing position tables

The axis positions (in mm or degrees) assigned to the indexes must be stored for each
indexing axis in the form of a table in machine data.
2 indexing position tables are possible:
MD10910 $MN_INDEX_AX_POS_TAB_1 [n] (indexing position table 1)
MD10930 $MN_INDEX_AX_POS_TAB_2 [n] (indexing position table 2)
Note
Several axes can be assigned to an indexing position table. On condition that these indexing
axes are of the same type (linear axis, rotary axis, modulo 360 function).
Extended Functions
T1: Indexing axes
No. of indexing positions

Up to 60 positions can be entered in each indexing position table:
[n = 0 ... 59]
The actually used number of entries is defined with the machine data:
MD10900 $MN_INDEX_AX_LENGTH_POS_TAB_1 ((number of positions of indexing
position table 1)
MD10920 $MN_INDEX_AX_LENGTH_POS_TAB_2 ((number of positions of indexing
position table 2)
Note
Entries in the indexing positions table that cross the parameterized number of indexing
positions (MD10900 or MD10920) are not considered.
Valid measuring system

The indexing positions defined with MD10900 and MD10920 are related to the measuring
system configured for position tables:
MD10270 $MN_POS_TAB_SCALING_SYSTEM
Value System of units

0 Metric
1 inch
Note
MD10270 has an effect on the following setting data:
SD41500 $SN_SW_CAM_MINUS_POS_TAB_1 (switching point for falling cam edge 1-8)
...
SD41507 $SN_SW_CAM_PLUS_POS_TAB_4 (switching point for rising cam edge 25-32)
Entry for indexing positions

The following rules apply:
The indexing positions must be entered in the table in ascending order (starting with the
negative to the positive traversing range) with no gaps between the entries.
Consecutive position values cannot be identical.
The axis positions must be entered in the basic coordinate system.
Extended Functions
T1: Indexing axes
15.4 Programming of indexing axes
Modulo rotary axis as indexing axis

The indexing axis is defined with Modulo 360 as rotary axis:
MD30300 $MA_IS_ROT_AX = 1
and
MD30310 $MA_ROT_IS_MODULO = 1
In this case, the following points must be observed additionally for the specification of the
indexing positions:
Permissible range: 0 Pos < 360
Since the indexing axis is defined as a continuously rotating rotary axis, indexing position
1 is approached after the highest valid indexing position in the table has been reached
and the axis continues to traverse in the positive direction with INC. Similarly, indexing
position 1 is followed by the highest valid indexing position in the negative direction with
INC.
Coded position
To allow indexing axes to be positioned from the NC part program, special instructions are
provided with which the indexing numbers (e.g. location numbers) are programmed instead
of axis positions in mm or degrees. The availability of a special instruction depends on the
axis type (linear or rotary axis):
Statement Effect Availability

CAC(i) Traverse coded position in absolute terms Linear axis, rotary axis
CACP(i) Traverse coded position ain absolute terms in Rotary axis
the positive direction
CACN(i) Traverse coded position ain absolute terms in Rotary axis
the negative direction
CDC(i) Traverse coded position along the direct Rotary axis
(shortest) path
CIC(i) Traverse coded position incrementally Linear axis, rotary axis
i: Coded position (indexing position)

Value range of i: 0 ... 59; whole number (positive and negative values are possible
in CIC)
Extended Functions
T1: Indexing axes
Examples

POS[B]=CAC(20) ; Indexing axis B approaches the coded position (indexing)
20 in absolute mode. The direction of traversing depends
on the current actual position.

POS[B]=CACP(10) ; Indexing axis B approaches the coded position (index
position ) 10 in absolute mode with positive direction of
rotation (possible only for rotary axes).

POS[B]=CACN(10) ; Indexing axis B approaches the coded position (index
position ) 10 in absolute mode with negative direction of
rotation (possible only for rotary axes).

POS[B]=CDC(50) ; Indexing axis B approaches indexing position 50 directly
along the shortest path (possible only for rotary axes).

POS[B]=CIC(-4) ; Indexing axis B traverses four indexing positions
incrementally from its current position. in a negative
direction.

POS[B]=CIC(35) ; Indexing axis B traverses 35 indexing positions
incrementally from its present position in a positive
direction.
Special features
Modulo rotary axis as indexing axis
On modulo rotary axes, the indexing positions are divided in factors of 360 and
approached directly.
Indexing axis is between two indexing positions
The specified position instructions have the following effect in the AUTOMATIC mode.
POS[B]=CIC(1)
The next higher indexing position is approached.
POS[B]=CIC(-1)
The next lower indexing position is approached.
POS[B]=CIC(0)
The indexing axis is not traversed.
Extended Functions
T1: Indexing axes
Display of indexing position

The number of the indexing position programmed last can be read with the following system
variables:
$AA_PROG_INDEX_AX_POS_NO
The number of the indexing position traversed last can be displayed with the following
system variables:
$AA_ACT_INDEX_AX_POS_NO
The display depends on the setting in machine data:
MD10940 $MN_INDEX_AX_MODE (settings for indexing position)
Bit Value Meaning

0 0 The indexing position changes when the indexing position is reached ("exact stop
fine" window) and remains unchanged until the next indexing position is reached. The
indexing area thus begins at one indexing position and ends in front of the next
indexing position.
1 The indexing position changes when half the indexing position is reached.
A quasi-symmetrical indexing area is thus applied around the indexing position
(symmetrical only on linear axes with equidistant indexing or modulo rotary axes on
which the indexing area is an integer multiple of the modulo range (MD30330
$MA_MODULO_RANGE), otherwise proportional to the distances between the
indexing positions).
On modulo rotary axes, the area between the last indexing position and the first
indexing position is divided proportionally based on the lengths of the first indexing
area and the last indexing area.
The following graphics will illustrate the difference between Bit 0 = 0 and Bit 0 = 1:
33
73$
(6):
%LW 73$ 73$ 73$ 73$ 73$ 73$
%LW 73$ 73$ 73$ 73$ 73$ 73$ 73$
Figure 15-1 Indexing position displays: Linear axis
Extended Functions
T1: Indexing axes
73$
73$
73$

73$

(6):
73$

73$
73$ 73$
%LW %LW
TP Programmed indexing position

TPA Displayed indexing position
ESFW "Exact stop fine" window
Figure 15-2 Indexing position displays: Modulo rotary axis
Value range of $AA_ACT_INDEX_AX_POS_NO

Expected value ranges of system variables $AA_ACT_INDEX_AX_POS_NO:
Indexing positions from table

Modulo rotary axis 1 ... n None 0
n = maximum 60
Linear axis 0*, 1, 2, 3, ... 59, 60, 61* 0*: below total indexing area
61*: above total indexing area
Equidistant indexing positions

Modulo rotary axis 1 ... m None 0
m = denominator (counter)
Linear axis ... -3, -2, -1, 0, 1, 2, 3, ...
Extended Functions
T1: Indexing axes
Traversing to the next indexing position

The response to the "Travel to the next indexing position" command depends on the setting
in machine data:
MD10940 $MN_INDEX_AX_MODE (settings for indexing position)
Bit Value Meaning

0 0 The next indexing position is approached.
1 The next indexing position in the direction of motion is always approached.
The following example will serve as explanation:

Bit 0 = 1 and axis below indexing position (but outside "exact stop fine" window).
Although the system variable $AA_ACT_INDEX_AX_POS_NO is indicating indexing position
2, indexing position 2 and not indexing position 3 is approached with the "Traverse to next
position" command. The next indexing position (in this case indexing position 3) is not
approached with the "Traverse to next position" command until the axis is located exactly at
(exact stop fine) or above the indexing position.
The nearest indexing position in the current direction of motion is always approached! Under
certain circumstances, it is thus necessary to transmit the "traverse to next position"
command twice to move from the currently displayed indexing position to the next indexing
position number (e.g. from 2 to 3).
FRAMES
Since the control interprets the positions stored in the indexing position table in mm, inches
or degrees, FRAMES are not interlocked on indexing axes.
FRAMES are not usually needed for indexing axes, depending on the area of application. It
is advisable in most cases to suppress FRAMES and work offsets for indexing axes in the
part program.
Extended Functions
T1: Indexing axes
15.5 Equidistant index intervals
15.5.1 Features
The following exist:
Any number of equidistant index intervals
Modified action of MD for indexing axes
Equidistant index intervals can be used for:
Linear axes
Modulo rotary axes
Rotary axes
Distance between indexes

The index distance is determined for equidistant index intervals according to the following
formula:
1XPHUDWRU0'0$B,1'(;B$;B180(5$725
'LVWDQFH
'HQRPLQDWRU0'0$B,1'(;B$;B'(120,1$725
Linear axis
0'0$B,1'(;B$;B2))6(7VWGLVWDQFHIURP]HURSRLQWSRVLWLYH

'LVWDQFHVWDQGDUGIRUDOOLQGH[LQJSRVLWLRQVVHHDERYH
0'0$B,1'(;B$;B2))6(7VWGLVWDQFHIURP]HURSRLQWQHJDWLYH

'LVWDQFHVWDQGDUGIRUDOOLQGH[LQJSRVLWLRQVVHHDERYH
Extended Functions
T1: Indexing axes
Modulo rotary axis
1XPHUDWRU0'0$B02'8/2B5$1*(
,QGH[
'HQRPLQDWRU0'0$B,1'(;B$;B'(120,1$725
0'0$B,1'(;B$;B2))6(7
r 6SDFLQJ

6L]HRIPRGXORUDQJH0'0$B02'8/2B5$1*(
,QGH[
1XPEHURILQGH[HVLQPRGXORUDQJH0'0$B,1'(;B$;B'(120,1$725
Activation
The functions with equidistant indexing for an axis (linear axis, modulo rotary axis or rotary
axis) is activated in the following settings
MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB[axis] = 3
15.5.2 Hirth tooth system
Function
With Hirth tooth systems, positions of rotation on a rotary axis are usually interlocked using a
latch or other toothed wheel via a linear axis. The interlock should only be activated when an
indexing position has been reached precisely. The distance between the indexing positions
is the same (equidistant) across the entire circumference.
Extended Functions
T1: Indexing axes
Requirements
The rotary axis must be an indexing axis. The axis must be referenced.
References:
Activation
Machine data:
MD30505 $MA_HIRTH_IS_ACTIVE (axis is an indexing axis with Hirth gearing)
must be set to 1.
Machine data:
MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB (axis is an indexing axis)
must be set to 3 (equidistant indexing positions).
Effect
The rotary axis can only approach indexing positions in all modes and operating states.
In JOG mode, the axis can be traversed under JOG control or incrementally.
Requirement: The axis is referenced.
Handwheel travel is not possible (see Section "H1: Manual and handwheel travel
(Page 143)").
Only "coded positions" can be approached in AUTO, MDA or via ASUBs.
The PLC can only move the axis to indexing positions.
15.5.3 Response of the Hirth axes in particular situations
STOP/RESET
For an NC Stop and Reset during a traversing movement, the next indexing position is
approached.
Emergency Stop
After an Emergency Stop, the PLC or the operator must move the indexing axis back to an
indexing position with JOG before the longitudinal axis can be moved in/down.
Override = 0 or signal "axis stopped"

If the axis has already moved away from the previous indexing position when these events
occur, the control moves the axis to the next possible indexing position before the response
is initiated.
Extended Functions
T1: Indexing axes
Delete distance-to-go
After traversing to the next possible indexing position, the movement is aborted at this
position.
Command axes
If MOV=0 is specified for a moving command axis, the axis continues traversing to the next
possible indexing position.
References:
MOV command
MOV=1
Works on indexing axes with and without Hirth tooth system.
MOV=0
Same function for both: Approaches the next position.
DELDTG command
In the case of indexing axes without Hirth tooth Axis stops immediately.
system:
In the case of indexing axes with Hirth tooth Axis traverses to next position.
system:
15.5.4 Restrictions
Transformations
The axis for which the Hirth tooth system is defined cannot take part in kinematic
transformations.
PRESET
The axis for which the Hirth tooth system is defined cannot be set to a new value with
PRESET.
The axis for which the Hirth tooth system is defined cannot be traversed at revolutional
feedrate.
Extended Functions
T1: Indexing axes
15.6 Starting up indexing axes
Path/velocity overlay
The axis for which the Hirth tooth system is defined cannot be used with path or velocity
overlay.
Frames, ext. work offset, DRF

The axis for which the Hirth tooth system is defined does not support frames or interpolation
compensation such as external work offsets, DRF, etc.
Couplings
A Hirth tooth system axis can never be one of the following axis types:
following axis with master value coupling
coupled-motion axis
gantry following axis
References:
Function Manual, Special Functions, Axis Couplings (M3)
15.5.5 Modified activation of machine data
RESET
A RESET is required in order to activate the following machine data after new values have
been assigned to them:
MD10900 $MN_INDEX_AX_LENGTH_POS_TAB_1
MD10920 $MN_INDEX_AX_LENGTH_POS_TAB_2
MD10910 $MN_INDEX_AX_POS_TAB_1
MD10930 $MN_INDEX_AX_POS_TAB_2
MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB
Procedure
The procedure for starting up indexing axes is identical to normal NC axes (linear and rotary
axes).
Extended Functions
T1: Indexing axes
Rotary axis
If the indexing axis is defined as a rotary axis (MD30300 $MA_IS_ROT_AX = "1") with
modulo 360 conversion (MD30310 $MA_ROT_IS_MODULO = "1"), indexing positions are
also approached with modulo 360o. Only positions within the range from 0 to 359.999 can
then be entered in the indexing position table. Otherwise alarm 4080 "Incorrect configuration
for indexing axis in MD [Name]" is output during power-up.
The position display can be set to modulo 360 as follows:
Special machine data

The following machine data must be set in addition:
General machine data

MD10900 $MN_INDEX_AX_LENGTH_POS_TAB_1 Number of positions for indexing axis
table 1
MD10920 $MN_INDEX_AX_LENGTH_POS_TAB_2 Number of positions for indexing axis
table 2
MD10910 $MN_INDEX_AX_POS_TAB_1 [n] Indexing position table 1
MD10930 $MN_INDEX_AX_POS_TAB_2 [n] Indexing position table 2
Axial machine data

MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis (assignment of
indexing position table 1 or 2, or 3 for
equidistant indexing)
MD30505 $MA_HIRTH_IS_ACTIVE Axis has "Hirth tooth system" property
MD30501 INDEX_AX_NUMERATOR Numerator for equidistant indexing
MD30502 INDEX_AX_DENOMINATOR Denominator for equidistant indexing
MD30503 INDEX_AX_OFFSET Distance of 1st indexing position from
zero
Examples
The assignment of the above machine data is described in the following paragraphs using
two examples.
Example 1: Indexing axis as rotary axis

Tool turret with 8 locations. The tool turret is defined as a continuously rotating rotary axis.
The distances between the 8 turret locations are constant. The first turret location is located
at position 0:
Extended Functions
T1: Indexing axes
,QGH[LQJ
SRVLWLRQ

r
r r
$[LVSRVLWLRQ
r r
r r
r

Figure 15-3 Example: Tool turret with 8 locations
The indexing positions for the tool turret are entered in indexing position table 1.
MD10910 $MN_INDEX_AX_POS_TAB_1[0] = 0 ; 1. indexing position at 0

MD10910 $MN_INDEX_AX_POS_TAB_1[1] = 45 ; 2. Indexing position at 45
Other machine data:
MD10900 $MN_INDEX_AX_LENGTH_POS_TAB_1= 8 ; 8 indexing positions in table

1
MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB [AX5] = 1 ;; Axis 5 is defined as
indexing axis
Indexing positions in table 1
MD30300 $MA_IS_ROT_AX [AX5] = 1 ; Axis 5 is rotary axis
MD30310 $MA_ ROT_IS_MODULO [AX5] = 1 ; Modulo conversion is
activated
Extended Functions
T1: Indexing axes
Example 2: Indexing axis as linear axis

Workholder with 10 locations.
The distances between the 10 locations are different. The first location is at position -100
mm.
,QGH[LQJSRVLWLRQ

$[LVSRVLWLRQ>PP@

Figure 15-4 Example: Workholder as an indexing axis
The indexing positions for the workholder are entered in table 2:
MD10930 $MN_INDEX_AX_POS_TAB_2[0] = -100 ; 1. indexing position at -100

Other machine data:
MD10920 $MN_INDEX_AX_LENGTH_POS_TAB_2=10 ; 10 indexing positions in table 2

MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB [AX6] = 2; Axis 6 is defined as indexing
axis, indexing positions in table
2
Extended Functions
T1: Indexing axes
15.7 Special features of indexing axes
15.7 Special features of indexing axes
DRF
An additional incremental work offset can also be generated for indexing axes in
AUTOMATIC mode with the handwheel using the DRF function.

The software limit switches are also effective during traversing movements once the indexing
axis has been referenced.
In handwheel traversing with JOG continuous or JOG incremental, the indexing axis stops at
the indexing position ahead of the software limit switch.

When reference point is reached::
DB31, ... DBX60.4 or 60.5 (referenced/synchronized 1 or 2) = 1
the indexing axis moves only to indexing positions in JOG continuous and JOG incremental
mode.
If the axis is not referenced:
DB31, ... DBX60.4 or 60.5 (referenced/synchronized 1 or 2) = 0,
the indexing positions are ignored when traversing in JOG mode!
Since the axis positions stored in the indexing position tables only correspond to the
machine positions when the axis is referenced, an NC start must be disabled for as long as
the indexing axis is not referenced.
Position display
Positions on indexing axes are displayed in the units of measurement normally used for the
axes (mm, inches or degrees).
Abort through RESET

RESETcauses the traversing movement on an indexing axis to be aborted and the axis to be
stopped. The indexing axis is no longer positioned on an indexing position.
Extended Functions
T1: Indexing axes
15.8 Examples
15.8 Examples
15.8.1 Examples of equidistant indexes
Modulo rotary axis

MD30502 $MA_INDEX_AX_DENOMINATOR[AX4] = 18
MD30503 $MA_INDEX_AX_OFFSET[AX4] = 5
MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB[AX4] = 3
MD30300 $MA_IS_ROT_AX[AX4] = TRUE
With the machine data above, axis 4 is defined as a modulo rotary axis and an indexing axis
with equidistant positions every 20 starting at 5.
The following indexing positions result:
5, 25, 45, 65, 85, 105, 125, 145, 165, 185, 205, 225, 245, 265, 285, 305, 325 and 245
degrees.
Note
The assignment:
MD30502 $MA_INDEX_AX_DENOMINATOR[AX4] =18
results in a 20 division because the default for machine data MD30330
$MA_MODULO_RANGE
is 360.
Rotary axis
MD30501 $MA_INDEX_AX_NUMERATOR[AX4] = 360
MD36100 $MA_POS_LIMIT_MINUS[AX1] = 100
With the machine data above, axis 4 is defined as a rotary axis and an indexing axis with
equidistant positions every 20 starting at 100.
100, 120, 140 etc.
Positions less than 100 cannot be approached as indexing positions.
It is advisable to place the lower software limit switch in this case. The indexing positions
continue until the software limit switch is reached (in this case 260). The rotary axis can
therefore only traverse between 100 and 260.
Extended Functions
T1: Indexing axes
15.8 Examples
Linear axis
MD30501 $MA_INDEX_AX_NUMERATOR[AX1] = 10
MD30503 $MA_INDEX_AX_OFFSET[AX1] = -200
MD30300 $MA_IS_ROT_AX[AX1] = FALSE
MD36100 $MA_POS_LIMIT_MINUS[AX1] = -200
With the machine data above, axis 4 is defined as a linear axis and an indexing axis with
equidistant positions every 10 mm starting at -200 mm.
-200, -190, -180 mm etc.
These indexing positions continue until the software limit switch is reached (in this case
200 mm).
Hirth tooth system

MD30505 $MA_HIRTH_IS_ACTIVE[AX4] = TRUE
With the machine data above, axis 4 is defined as a modulo rotary axis and an indexing axis
with Hirth tooth system and equidistant positions every 1 starting at 0.
Extended Functions
T1: Indexing axes
15.9 Data lists
15.9 Data lists
15.9.1 Machine data

10260 CONVERT_SCALING_SYSTEM Basic system switchover active
10270 POS_TAB_SCALING_SYSTEM System of measurement of position tables
10900 INDEX_AX_LENGTH_POS_TAB_1 Number of positions for indexing axis table 1
10910 INDEX_AX_POS_TAB_1[n] Indexing position table 1
10920 INDEX_AX_LENGTH_POS_TAB_2 Number of positions for indexing axis table 2
10930 INDEX_AX_POS_TAB_2[n] Indexing position table 2
10940 INDEX_AX_MODE Options for indexing positions

30300 IS_ROT_AX Rotary axis
30310 ROT_IS_MODULO Modulo conversion for rotary axis
30320 DISPLAY_IS_MODULO Position display is modulo 360
30500 INDEX_AX_ASSIGN_POS_TAB Axis is indexing axis
30501 INDEX_AX_NUMERATOR Numerator for indexing axes with equidistant positions
30502 INDEX_AX_DENOMINATOR Denominator for indexing axes with equidistant
positions
30503 INDEX_AX_OFFSET Indexing position for indexing axes with equidistant
positions
30505 HIRTH_IS_ACTIVE Hirth tooth system is active
15.9.2 Setting data

41050 JOG_CONT_MODE_LEVELTRIGGRD JOG continuous in inching mode
Extended Functions
T1: Indexing axes
15.9 Data lists
15.9.3 Signals

Referenced/synchronized 1, referenced/synchronized 2 DB31, ... .DBX60.4/5 DB390x.DBX0.4/5
Indexing axis in position DB31, ... .DBX76.6 DB390x.DBX1002.6
$AA_ACT_INDEX_AX_POS_NO[axis] Number of last indexing position reached or overtraveled
$AA_PROG_INDEX_AX_POS_NO[axis] Number of programmed indexing position
Extended Functions
W3: Tool change 16
Tool change
CNC-controlled machine tools are equipped with tool magazines and automatic tool change
facility for the complete machining of workpieces.
Sequence
The procedure for changing tools comprises three steps:
1. Movement of the tool carrier from the machining position to the tool change position
2. Tool change
3. Movement of the tool carrier from the tool change position to the new machining position.
Requirements
The following is required for tool change:
short idle times
Time-saving searches, provision and return of tool during the machining time.
Simple programming of the tool change cycle
Automatic flow of the required axis and gripper movements
Easy fault recovery
16.2 Tool magazines and tool change equipments

Tool magazines and tool changing equipment are selected according to the machine type:
Machine type Tool magazine Tool change equipment

Turning machines Turret No special tool change equipment.
(disk, flat, inclined) The tool is changed by turning the
turret
Milling machines Magazines Gripper/dual gripper as tool change
(chain, disk-type, rotary-plate, cartridge) equipment.
As the changing operation interrupts the machining, idle times times must be minimized.
Extended Functions
W3: Tool change
16.3 Tool change times
16.3 Tool change times

Tool change times depend strongly on the design layout of the machine tool.
Typical tool change times

0.1 to 0.2 s for advancing a turret
0.3 to 2 s for tool change with gripper for a prepared tool
16.4 Cut-to-cut time

The cut-to-cut time is the period that elapses when a tool is changed between retraction from
the interruption point on the contour (from cut) and repositioning at the interruption point
(return to cut) with the new tool when the spindle is rotating.
Typical cut-to-cut times are as follows:
Typical cut-to-cut times

0.3 to 1 s for turning machine with turret
0.5 to 5 s for milling machine with automatic tool changer
16.5 Starting the tool change
Variants
The tool change can be actuated by:
T function
M command (preferably M06)
Parameterization
Which control versions should be effective is defined with the machine data:
MD22550 $MC_TOOL_CHANGE_MODE
Value Meaning Typical application

0 The T function loads the new tool immediately. Turning machines with tool turret
1 New tool with T function prepared for change and Milling machines with a tool magazine,
placed in the tool change position simultaneously
during the machining time.
The M command is used to remove the old tool
from the spindle and load the new tool.
Extended Functions
W3: Tool change
16.6 Tool change point
The M command for tool change is defined in machine data:

MD22560 $MC_TOOL_CHANGE_M_CODE
Default setting is 6 (corresponding to DIN 66025).
Note
If the tool offset number is supplied from the PLC or an HMI tool manager, a preprocessing
stop STOPRE must be inserted at a suitable point. STOPRE must be avoided, however,
when tool radius compensation (G41 / G42) or SPLINE interpolation is active, since several
blocks are required here in advance for the path calculation.
References
For further information about M functions which also apply to tool change M06 (e.g.
extended address, time of output to PLC, auxiliary function groups, behavior during block
search, behavior during overstore) see:
16.6 Tool change point
Tool change point

The selection of the tool change point has a significant effect on the cut-to-cut time
(Page 796). The tool change point is chosen according to the machine tool concept and, in
certain cases, according to the current machining task.
Approaching a fixed point

Fixed positions on a machine axis stored in machine data can be approached by means of
the "fixed-point approach" function. This can be used to define and control one or several
tool change points.
There are two fixed point approach options:
Approaching a fixed point in JOG
The machine user starts the "fixed-point approach" in the JOG mode with the traverse
keys or the handwheel (see Section "Approaching a fixed point in JOG (Page 183)").
Approaching a fixed point with G75
Fixed point approach is called using the command G75 from the part program.
References:
Programming Manual, Fundamentals, Section: Additional commands > Approach fixed
point (G75)
Extended Functions
W3: Tool change

The tool change requires, amongst other things, a tool management system which ensures
that the tool to be loaded is available at the tool change position at the right time.
16.8 Examples
Milling machine
The following example shows a typical cut-to-cut sequence of operations for a tool change
with a tool changer and a fixed absolute tool change point on a milling machine.
Machining program:

N970 G0 X=... Y=... Z=... LF ; Retraction from contour
N980 T1 LF ; Tool preselection
N990 W_WECHSEL LF ; Subroutine call without
parameters
N1000 G90 G0 X=... Y=... Z=... M3 S1000 LF ; Continue machining
Subroutine for tool change:

PROC W_WECHSEL LF
N10 SPOSA=... S0 LF ; Spindle positioning
N20 G75 FP=2 X1=0 Y1=0 Z1=0 ; Approach tool change position
N30 M06 LF ; Change tool
N40 M17 LF
Extended Functions
W3: Tool change
16.8 Examples
1 1
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t2 : Move axes to tool change point with G75 in N20.
t3 : Spindle reaches programmed position from block N10.
t4 : Axes reach exact stop coarse from N20; N30 thus begins:
M06 removes the previous tool from the spindle and loads and clamps the new tool.
t5: Tool changer swivels back to original position.
Figure 16-1 Chronological sequence of tool change
Then, in N1000 of the calling main program:

The new tool offset can be selected
the axes can be returned to the contour, or
the spindle can be accelerated.
Extended Functions
W3: Tool change
16.9 Data lists
16.9 Data lists
16.9.1 Machine data

18082 MM_NUM_TOOL Number of tools

22200 AUXFU_M_SYNC_TYPE Output timing of M functions
22220 AUXFU_T_SYNC_TYPE Output timing of T functions
22550 TOOL_CHANGE_MODE New tool offset for M function
22560 TOOL_CHANGE_M_CODE M function for tool change
16.9.1.3 Axis-/spindlespecific machine data

30600 FIX_POINT_POS[n]. Fixed point positions of the machine axes for G75
16.9.2 Signals

M function M06 DB21, ... .DBX194.6 DB2500.DBB1000.6
Extended Functions
W4: Grinding-specific tool offset and tool monitoring 17
Contents
The topics of this functional description are:
Grinding-specific tool offset
Online tool offsets (continuous dressing)
Grinding-specific tool monitoring
Constant grinding wheel peripheral speed (GWPS)
References
For fundamentals see:
Function Manual Basic Functions; Tool Offset (W1)
Programming, mode of operation and handling, please refer to:
Programming Manual, Fundamentals
17.1 Tool offset for grinding operations
17.1.1 Structure of tool data
Grinding tools
Grinding tools are tools of types 400 to 499.
Tool offset for grinding tools

Grinding tools normally have specific tool and dresser data in addition to cutting edge data.
The specific grinding wheel data for the left and right wheel geometry can be stored under a
T number in D1 and D2.
If data are needed for the dresser geometry, they can be stored, e.g., starting at D3 of a T
number or in additional cutting-edge-specific data
(MD18096 $MN_MM_NUM_CC_TOA_PARAM).
Extended Functions
W4: Grinding-specific tool offset and tool monitoring
Example 1:
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All offsets belonging to a grinding wheel and dresser can be combined in the tool edges D1
and D2 for the grinding wheel and, for example, D3 and D4 for the dresser:
D1: grinding wheel geometry left
D2: Grinding wheel geometry right
D3: Dresser geometry left
D4: Dresser geometry right
Extended Functions
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Figure 17-1 Structure of tool offset data for grinding tools
17.1.2 Edge-specific offset data
Tool parameter
The tool parameters for grinding tools have the same meaning as those for turning and
milling tools.
Tool parameter Meaning Comment

1 Tool type
2 Cutting edge position For turning and grinding
tools only
Geometry tool length compensation
3 Length 1
4 Length 2
5 Length 3
Geometry tool radius compensation
6 Radius 1
7 Reserved
8 Reserved
9 Reserved
10 Reserved
11 Reserved
Wear tool length compensation
12 Length 1
13 Length 2
14 Length 3
Extended Functions
Tool parameter Meaning Comment

Wear tool radius compensation
15 Radius 1
16 Reserved
17 Reserved
18 Reserved
19 Reserved
20 Reserved
Tool base dimension / adapter dimension tool length compensation
21 Basic length 1
22 Basic length 2
23 Basic length 3
Technology
24 Undercut angle For turning tools only
25 Reserved
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Note
The cutting edge data for D1 and D2 of a selected grinding tool can be chained, i.e. if a
parameter in D1 or D2 is modified, then the same parameter in D1 or D2 is automatically
overwritten with the new value (see tool-specific data $TC_TPG2).
Extended Functions
Definition of additional parameters $TC_DPC1...10

For user-specific cutting edge data, additional parameters $TC_DPC1 to 10 can be set up
independent of the tool type using the following general machine data:
MD18096 $MN_MM_NUM_CC_TOA_PARAM
CAUTION
Data loss
Changes to MD18096 take effect after power on and will lead to initialization of the
memory.
A data backup must be created beforehand.
CAUTION
No grinding wheel offset changeover
Automatic changeover between grinding wheel offset left and right does not take place
during contour grinding.
A changeover must be programmed.
Tool types for grinding tools

The structure of tool types for grinding tools is as follows:
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Note
MD20350 $MC_TOOL_GRIND_AUTO_TMON
Through this channel-specific machine data it can be determined, whether for grinding tools
with monitoring (i.e. uneven tool types) the monitoring is already active or not when this tool
is selected.
Extended Functions
This structure can be used to create the following tool types:
Type Description
400 Surface grinding wheel
401 Surface grinding wheel with monitoring with tool base dimension for GWPS
402 Surface grinding wheel without monitoring without tool base dimension for GWPS
403 Surface grinding wheel with monitoring without tool base dimension for GWPS
410 Facing wheel
411 Facing wheel with monitoring with tool base dimension for GWPS
412 Facing grinding wheel without monitoring without tool base dimension for GWPS
413 Facing wheel with monitoring without tool base dimension for GWPS
490 Dresser
17.1.3 Tool-specific grinding data
Tool-specific grinding data

Tool-specific grinding data is available once for every T number (type 400- 499). The data is
automatically set up with every new grinding tool (type 400 - 499).
Note
Tool-specific grinding data has the same characteristics as a tool edge.
This is to be taken into account when the number of cuts is specified:
MD18100 $MN_MM_NUM_CUTTING_EDGES_IN_TOA
When all the cutting edges of a tool are deleted, the existing tool-specific grinding data is
deleted at the same time.
Parameters
The parameters are assigned as follows:
Parameter Meaning Data type

$TC_TPG1 Spindle number Integer
$TC_TPG2 Chaining rule Integer
$TC_TPG3 Minimum wheel radius Real
$TC_TPG4 Minimum wheel width Real
$TC_TPG5 Current wheel width Real
$TC_TPG6 Maximum speed Real
$TC_TPG7 Maximum peripheral speed Real
$TC_TPG8 Angle of inclined wheel Real
$TC_TPG9 Parameter number for radius calculation Integer
Extended Functions
Parameter Meaning Data type

Additional parameters (user-specific cutting edge data)
$TC_TPC1 Real
to
$TC_TPC10
Definition of additional parameters $TC_DPC1...10

For the user-specific cutting data the additional parameters $TC_DPC1 to $TC_DPC10 can
be implemented independent of the WZ-type. This is done via the general machine data:
MD18096 $MN_MM_NUM_CC_TDA_PARAM
CAUTION
Data loss
Changes to MD18096 take effect after power on and will lead to initialization of the
memory.
A data backup must be created beforehand.
Spindle number $TC_TPG1

Number of the programmed spindle (e.g. grinding wheel peripheral speed) and spindle to be
monitored (e.g. wheel radius and width)
Chain rule $TC_TPG2

This parameter is set to define which tool parameters of tool edge 2 (D2) and tool edge 1 (D1)
have to be chained to one another. When the setpoint of a chained parameter is modified,
the value of the parameter with which it is chained is modified automatically.
Tool parameter Meaning Bit in $TC_TPG2 Hex Dec

$TC_DP1 Tool type 0 0001 1
$TC_DP2 Length of cutting edge 1 0002 2
Geometry tool length compensation
$TC_DP3 Length 1 2 0004 8
$TC_DP4 Length 2 3 0008 16
$TC_DP5 Length 3 4 0010 32
$TC_DP6 Radius 5 0020 64
$TC_DP7 Reserved 6 0040 128
$TC_DP8 7 0080 256
$TC_DP9 8 0100 512
$TC_DP10 9 0200 1024
$TC_DP11 Reserved 10 0400 2048
Extended Functions
Tool parameter Meaning Bit in $TC_TPG2 Hex Dec

Wear tool length compensation
$TC_DP12 Length 1 11 0800 4096
$TC_DP13 Length 2 12 1000 8192
$TC_DP14 Length 3 13 2000 16384
$TC_DP15 Radius 14 4000 32768
$TC_DP16 Reserved 15 8000 65536
$TC_DP17 16 10000 131072
$TC_DP18 17 20000 262144
$TC_DP19 18 40000 524288
$TC_DP20 Reserved 19 80000 1048576
Tool base dimension / adapter dimension tool length compensation
$TC_DP21 Basic length 1 20 100000 2097152
Technology
$TC_DP24 Reserved 23 800000 16777216
$TC_DP25 Reserved 24 1000000 33554432
Example of parameter chain:

Lengths 1, 2 and 3 of the geometry, the length wear and the tool base / adapter dimensions
of lengths 1, 2 and 3 on a grinding tool (T1 in the example) must be automatically
transferred.
Furthermore, the same tool type applies to tool edges 1 and 2.
Tool type $TC_DP1 Bit 0

Length 1 $TC_DP3 Bit 2
Wear
Base/adapter dimension
Extended Functions
Parameter $TC_TPG2 must therefore be assigned as follows:
Binary: $TC_TPG2[1]= 'B111 0000 0011 1000 0001 1101'

(Bit 22 ... Bit 0)
Hexadecimal: $TC_TPG2[1]= 'H70381D'
Decimal: $TC_TPG2[1]='D7354397'
Note
If the chaining specification is subsequently altered, the values of the two cutting edges are
not automatically adjusted, but only after one parameter has been altered.
Minimum wheel radius and width $TC_TPG3 $TC_TPG4

The limit values for the grinding wheel radius and width must be entered in these
parameters. These parameter values are used to monitor the grinding wheel geometry.
Note
It must be noted that the minimum grinding wheel radius must be specified in the Cartesian
coordinate system for an inclined grinding wheel. A signal is output at the PLC interface if the
grinding wheel width and radius drop below the minimum limits. Users can use these signals
to define their error strategy.
Current width $TC_TPG5

The width of the grinding wheel measured, for example, after the dressing operation, is
entered here.
Maximum speed and grinding wheel peripheral speed $TC_TPG6 $TC_TPG7

The upper limit values for maximum speed and peripheral speed of the grinding wheel must
be entered in these parameters.
Precondition: A spindle has been declared.
Extended Functions
Angle of inclined wheel $TC_TPG8

This parameter specifies the angle of inclination of an inclined wheel in the current plane. It
is evaluated for GWPS.
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Note
The tool lengths are not automatically compensated when the angle is altered.
The angle must be within the range -90 $TC_TPG8 < +90.
On inclined axis machines the same angle must be specified for the inclined axis and the
inclined wheel.
Parameter number for radius calculation $TC_TPG9

This parameter specifies which offset values are used for the GWPS calculation and tool
monitoring of the minimum wheel radius ($TC_TPG3).
$TC_TPG9 = 3 Length 1 (geometry + wear + base, depending on tool type)

$TC_TPG9 = 6 Radius
Extended Functions
Access from part program

Parameters can be read and written from the part program.
Example Programming
Read the current width of tool 2 and store in R10 R10 = $TC_TPG5 [2]
Write value 2000 to the maximum speed of tool 3 $TC_TPG6 [3] = 2000
$P_ATPG[m] for current tool

This system variable allows the tool-specific grinding data for the current tool to be
accessed.
m: Parameter number (data type: Real)
Example:
Parameter 3 ($TPG3[<T No.>])
$P_ATPG[3]=R10
Note
The monitoring data applies to both the left-hand and the right-hand cutting edge of the
grinding wheel.
The tool-specific grinding data is activated when GWPSON (select constant grinding wheel
surface speed) and TMON (select tool monitoring) are programmed. To activate a data item
that has been modified, it is necessary to program GWPSON or TMON again.
The length compensations always specify the distances between the tool carrier reference
point and the tool tip in the Cartesian coordinates (must be noted for inclined grinding
wheel).
Extended Functions
17.1.4 Examples of grinding tools
Assignment of length offsets

Tool length compensations for the geometry axes or radius compensation in the plane are
assigned on the basis of the current plane.
Planes
The following planes and axis assignments are possible (abscissa, ordinate, applicate for
1st, 2nd and 3rd geometry axes):
Command Plane Axis perpendicular to plane

(abscissa/ordinate) (applicate)
G17 X/Y Z
G18 Z/X Y
G19 Y/Z X
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Extended Functions
Surface grinding wheel
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Extended Functions
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base selection for GWPS calculation
Extended Functions
Surface grinding wheel
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Extended Functions
17.2 Online tool offset
Application
A grinding operation involves both machining of a workpiece and dressing of the grinding
wheel. These processes can take place in the same channel or in separate channels.
To allow the wheel to be dressed while it is machining a workpiece, the machine must offer a
function whereby the reduction in the size of the grinding wheel caused by dressing is
compensated on the workpiece. This type of compensation can be implemented by means of
the "Online tool offset" (Continuous Dressing) function.
Dressing during machining process

To allow machining to continue while the grinding wheel is being dressed, the reduction in
the size of the grinding wheel caused by dressing must be transferred to the current tool in
the machining channel as a tool offset that is applied immediately.
This parallel dressing operation can be implemented by means of the "Continuous Dressing
(parallel dressing), Online tool offset" function.
Note
The online tool offset may only be used for grinding tools.
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Extended Functions
General information
An online tool offset can be activated for every grinding tool in any channel.
The online tool offset is generally applied as a length compensation. Like geometry and wear
data, lengths are assigned to geometry axes on the basis of the current plane as a function
of the tool type.
The grinding spindle monitoring function remains active when an online tool offset is
selected.
Note
The offset always corrects the wear parameters of the selected length. If the length
compensation is identical for several cutting edges, then a chaining specification must be
used to ensure that the values for the 2nd cutting edge are automatically corrected as well.
If online offsets are active in the machining channel, then the wear values for the active tool
in this channel may not be changed from the machining program or via operator inputs.
Modifications to the radius wear (P15) are not taken into account until the tool is reselected.
The online offset is also applied to the constant grinding wheel peripheral speed (GWPS),
i.e. the spindle speed is corrected by the corresponding value.
Instructions
The following commands are provided for online tool offsets:
Command Meaning
FCTDEF Parameterize function
<polynomial no.>, <lower limit>, <upper limit>, <coefficient 0>, (up to 3rd degree polynomial)
<coefficient 1>, <coefficient 2>, <coefficient 3>) (Fine Tool Offset Definition)
PUTFTOCF Write online tool offset
(<polynomial no.>, <reference value>, <length1_2_3>, <channel continuously
no.>, <spindle no.>) (Put Fine Tool Offset Compensation)
PUTFTOC Write online tool offset
(<value>, <length1_2_3>, <channel no.>, <spindle no.>) discretely
(Put Fine Tool Offset Compensation)
FTOCON Activation of online tool offset
(Fine Tool Offset Compensation ON)
FTOCOF Deactivation of online tool offset
(Fine Tool Offset Compensation OFF)
Note
Changes to the correction values in the TOA memory do not take effect until T or D is
programmed again.
References:
Programming Manual, Job Planning
Extended Functions
17.2.2 Write online tool offset: Continuous
FCTDEF
Certain dressing strategies (e.g. dressing roller) are characterized by the fact that the
grinding wheel radius is continuously (linearly) reduced as the dressing roller is fed in. This
strategy requires a linear function between infeed of the dressing roller and writing of the
wear value of the respective length.
Function FCTDEF allows 3 independent functions to be defined according to the following
syntax:
Function parameters
The function parameters are set in a separate block according to the following syntax:
FCTDEF(<polynomial no.>, <lower limit>, <upper limit>, <coefficient a0>, <coefficient a1>,
<coefficient a2>, <coefficient a3>)
FCTDEF
Function definition
Polynomial no.: Number of function (e.g. 1, 2 or 3)
Lower/upper limit: Determines value range of the function
(limit values in input resolutions)
Coefficients a0, a1, a2: Coefficients of polynomial
A 3rd degree polynomial is generally defined as follows:

y = a0 + a1 * x + a2 * x2 + a3 * x3
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Note
FCTDEF must be programmed in a separate NC block.
Extended Functions
Example:
Existing conditions: Lead: a1 = +1

a2 = 0
a3 = 0
At the time of definition, the function value y should be equal to 0 and
should be derived from machine axis XA (e.g. dresser axis).
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Write online tool offset continuously

PUTFTOCF(<polynomial no.>, <reference value>, <length1_2_3>, <channel no.>, <spindle
no.>)
PUFTOCF
Polynomial no.: Number of function (1, 2, 3)
Reference value: Reference value of function
Length 1_2_3: Wear parameter into which the tool offset value is added
Channel no.: Channel in which the offset is to be effective
Spindle no.: Spindle for which the online offset is to be effective
The online tool offset is activated before the dresser axis movement block.
Example:

FCTDEF(1,-100,100,-$AA_IW[X],1) ; Function definition
PUTFTOCF(1,$AA_IW[X],1,2,1) ; Write online tool offset continuously
Extended Functions
Length 1 of tool for spindle 1 in channel 2 is modified as a function of X axis movement.
Note
The online tool offset for a (geometric) grinding tool that is not active can be activated by
specifying the appropriate spindle number.
If the channel number is omitted, the online offset is effective in the same channel.
If the spindle number is omitted, the online offset is applied to the current tool.
An online tool offset can also be called as a synchronized action.

References:
17.2.3 Activate/deactivate online tool offset
Activation/deactivation of online tool offset

The following commands activate and deactivate the online tool offset in the machining
channel (grinding, destination channel):
FTOCON
Activation of online tool offset
The machining channel can process online tool offsets (PUTFTOC) only if the
offset is active (FTOCON). Alarm 20204 "PUTFTOC command not allowed" is
otherwise output.
FTOCOF
Deactivation of online tool offset
FTOCOFdeactivates the online tool offset. The written values remain stored in the
appropriate length compensation data.
Online offsets are traversed in the basic coordinate system, i.e. even when the workpiece
coordinate system has been rotated, the length compensations always act in parallel to the
coordinates of the unrotated system.
The offset is applied regardless of whether or not the axis to be compensated is traversed in
the current block.
Note
Command FTOCON must be written to the channel in which the offset is to be applied
(machining channel for grinding operation).
FTOCOF always corresponds to the reset position. PUTFTOC commands are effective only when
the part program and FTOCON command are active.
Extended Functions
17.2.4 Example of writing online tool offset continuously
Surface grinding machine
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Y: Infeed axis for grinding wheel

V: Infeed axis for dressing roller
X: Reciprocating axis, left - right
Plane for the tool offset: G19 (Y/Z plane)

Length 1 acts in Z, length 2 in Y, tool type = 401
Machining: Channel 1 with axes Y, X

Dressing: Channel 2 with axis V
Task
After the grinding operation has started at Y100, the grinding wheel must be dressed by 0.05
(in V direction). The dressing amount must be compensated continuously by means of an
online offset.
Extended Functions
Main machining program in channel 1

...
G1 G19 F10 G90 ; Basic position
T1 D1 ; Select current tool
S100 M3 Y100 ; Spindle On, traverse to
; Starting position
FTOCON ; Activate online offset
INIT (2, "/_N_MPF_DIR/_N_ABRICHT_MPF", "S") ; Select program
; in channel 2
START (2) ; Starting the program
; in channel 2
Y200 ; Travel to target position

...
M30
Dressing program in channel 2_N_ABRICHT_MPF

...
FCTDEF (1, -1000, 1000, -$AA_IW[V], 1) ; Function definition
PUTFTOCF (1, $AA_IW[V], 2, 1) ; Write online tool offset
; Continuous
U-0.05 G1 F0.01 G91 ; Infeed movement to dress wheel
...
M30
Note
Axis V operates (dresses) in parallel to Y, i.e. length 2 acts in Y and must therefore be
compensated.
Extended Functions
17.2.5 Write online tool offset discretely
PUTFTOC
This command writes an offset value by means of a program command.
PUTFTOC(<value>, <length1_2_3>, <channel no.>, <spindle no.>)
Put Fine Tool Offset Compensation
The wear of the specified length (1, 2 or 3) is modified online by the programmed value.
Note
The online tool offset for a (geometric) grinding tool that is not active can be activated by
specifying the appropriate spindle number.
If the channel number is omitted, the online offset is effective in the same channel.
If the spindle number is omitted, the online offset is applied to the current tool.
17.2.6 Information about online offsets
Response in the case of tool change

In cases where FTOCON has been active since the last tool or cutting edge change,
preprocessing stop with resynchronization is initiated in the control when a tool is
changed.
Cutting edge changes can be implemented without preprocessing stop.
Note
Tool changes can be executed in conjunction with the online tool offset through the
selection of T numbers.
Tool changes with M6 cannot be executed in conjunction with the online tool offset
function.
Machining plane and transformation

FTOCON can be used only in conjunction with the "Inclined axis" transformation.
It is not possible to change transformations or planes (e.g. G17 to G18) when FTOCON is
active, except in the FTOCOF state.
Extended Functions
17.3 Online tool radius compensation
Resets and operating mode changes

When online offset is active, NC-STOP and program end with M2/M30 are delayed until the
amount of compensation has been traversed.
The online tool offset is immediately deselected in response to NC-RESET.
Online tool offsets can be activated in AUTOMATIC mode and when the program is
active.
The online tool offset is superimposed on the programmed axis motion, allowing for the
defined limit values (e.g. velocity).
If a DRF offset and online offset are active simultaneously for an axis, the DRF offset is
considered first.
The pending offset is traversed at JOG velocity, allowing for the maximum acceleration.
In case of FTOCON the following channel-specific machine data is taken into account:
MD20610 $MC_ADD_MOVE_ACCEL_RESERVE
An acceleration margin can thus be reserved for the movement which means that the
overlaid movement can be executed immediately.
The valid online offset is deleted on reference point approach with G74.
The fine offset is not deselected for tool changes with M6.
17.3 Online tool radius compensation
General information
When the longitudinal axis of the tool and the contour are perpendicular to each other, the
offset can be applied as a length compensation to one of the three geometry axes (online
tool length compensation).
If this condition is not fulfilled, then the offset quantity can be entered as a real radius
compensation value (online tool radius compensation).
Enabling of function
The online tool-radius offset is activated via the machine data:
MD20254 $MC_ONLINE_CUTCOM_ENABLE (enable online tool radius compensation).
Activation/deactivation
An online tool radius compensation is activated and deactivated by means of commands
FTOCON and FTOCOF
(in the same way as an online tool length compensation).
Extended Functions
17.4 Grinding-specific tool monitoring
Parameterization
The parameters of the online tool offset are set using commands PUTFTOCF and PUTFTOC.
Parameter "LENGTH 1_2_3" must be supplied as follows for an online tool radius
compensation:
Parameter <length 1_2_3> = 4
Wear parameter to which correction value is added.
A tool radius compensation, and thus also an online tool radius compensation, can be
activated only when the selected tool has a radius other than zero. This means that
machining operations cannot be implemented solely with a tool radius compensation.
The online offset values should be low in comparison to the original radius to prevent the
permitted dynamic tolerance range from being exceeded when the offset is overlaid on
the axis movement.
When online tool radius compensation is applied to grinding and turning tools (types 400-
599), the compensation value is applied as a function of the tool point direction, i.e. it acts
as a radius compensation when tool radius compensation is active and as a length
compensation when tool radius compensation is deactivated in the axes specified by the
tool point direction.
On all other tool types, the compensation value is applied only when tool radius
compensation has been activated with G41 or G42. The compensation value is canceled
when tool radius compensation is deactivated with G40.
Activation
The tool monitoring function is a combination of geometry and speed monitors and can be
activated for any grinding tool (tool type: 400 to 499).
Extended Functions
Selection
The monitoring function is selected:
by programming (TMON) in the part program
or
automatically through selection of tool length compensation of a grinding tool with uneven
tool type number.
Note
The automatic selection of the monitoring must be set via the channel-specific machine
data:
MD20350 $MC_TOOL_GRIND_AUTO_TMON.
Monitoring active
The monitor for a grinding tool remains active until it is deselected again by means of
program command TMOF.
Note
Monitoring of one tool is not deselected if the monitoring function is selected for another tool
provided the two tools are referred to different spindles.
One tool and thus also one tool monitor can be active for every spindle at any point in time.
Activated monitors remain active after a RESET.
17.4.2 Geometry monitoring
Function
The following quantities can be monitored:
The current grinding wheel radius
and
The current grinding wheel width
The current wheel radius is compared with the value stored in parameter $TC_TPG3.
The current radius is compared with the parameter number of the first edge (D1) of a grinding
tool declared in parameter $TC_TPG9.
The current wheel width is generally calculated by the dressing cycle and can be entered in
parameter $TC_TPG5 of a grinding tool. The value entered in this parameter is compared to
the value stored in parameter $TC_TPG4 when the monitoring function is active.
Extended Functions
When does monitoring take place?

The monitoring function for the grinding wheel radius remains active when an online tool
offset is selected:
When the monitoring function is activated
when the current radius (online tool offset, wear parameter) or the current width
($TC_TPG5) is altered
Monitor reactions
If the current grinding wheel radius becomes smaller than the value stored in parameter
$TC_TPG3 or the current grinding wheel width ($TC_TPG5) drops below the value defined
in $TC_TPG4, the axis/spindle-specific bit DBX83.3 is set to "1" in DB31, ... at the PLC
interface.
This bit is otherwise set to "0".
DB31, ... DBX83.3 = 1 Geometry monitoring has responded
DB31, ... DBX83.3 = 0 Geometry monitoring has not responded
Note
No error reaction is initiated internally in the control system.
17.4.3 Speed monitoring
Function
The speed monitor checks the grinding wheel peripheral speed (parameter $TC_TPG7) as
well as the maximum spindle speed (parameter $TC_TPG6).
The unit of measurement is:
Grinding wheel peripheral speed m * s-1
Spindle speed rev/min
Monitoring is cyclic. The value is always limited to the first limit value reached.
When does monitoring take place?

The speed setpoint is monitored against the speed limitation cyclically, allowing for the
spindle override.
Extended Functions
When is the speed limit value recalculated?

The speed limit value is recalculated:
when the monitoring function is selected,
when the online offset values (wear parameters) are altered.
Monitor reactions
The system reacts as follows when the speed monitor responds:
The speed is restricted to the limit value
and
Interface signal:
DB31, ... DBX83.6 (speed monitoring)
is output.
DB31, ... DBX83.6 = 1 Speed monitoring limit reached
DB31, ... DBX83.6 = 0 Speed monitoring limit not reached
Note
No error reaction is initiated internally in the control system.
17.4.4 Selection/deselection of tool monitoring
Part program commands

The following part program commands are provided for selecting and deselecting the
grinding-specific tool monitor of an active or inactive tool:
Command Meaning
TMON Selection of tool monitoring for the active tool in the channel.
Tool monitoring ON
TMOF Deselection of tool monitoring for the active tool in the channel.
Tool monitoring OFF
TMON (T number) Selection of tool monitoring for a non-active tool with T number.
Tool monitoring ON (T No.)
TMOF (T number) Deselection of tool monitoring for a non-active tool with T number.
Tool monitoring OFF (T No.)
TMOF (0) Deselection of tool monitoring for all tools.
Tool monitoring OFF (0)
Extended Functions
17.5 Constant grinding wheel peripheral speed (GWPS).
What is GWPS?
A grinding wheel peripheral speed, as opposed to a spindle speed, is generally programmed
for grinding wheels. This variable is determined by the technological process (e.g. grinding
wheel characteristics, material pairing). The speed is then calculated from the programmed
value and the current wheel radius.
Note
GWPS can be selected for grinding tools (types 400- 499).
Speed calculation
The formula for calculating the speed is as follows:
*:3>P V@

Q>USP@
5>P@
Note
Grinding wheel peripheral speed can be programmed and selected for grinding tools (types
400- 499).
The wear is considered when calculating the radius (parameter $TC_TPG9).
This function also applies to inclined wheels/axes.
The associated wear and the base dimension as a function of the tool type are added to the
parameter selected by $TC_TPG9.
The sum total is divided by "cos" ($TC_TPG8) when the value of parameter $TC_TPG8
(angle of inclined wheel) is positive, and is divided by "sin" ($TC_TPG8) when the value is
negative.
When is the speed recalculated?

The speed is recalculated in response to the following events:
GWPS programming
Change in the online offset values (wear parameters).
Extended Functions
17.5.2 Selection/deselection and programming of GWPS, system variable
Part program commands

The GWPS is selected and deselected with the following part program commands:
Command Meaning
GWPSON Selection of GWPS for the active tool in the
Grinding wheel peripheral speed ON channel.
GWPSOF Deselection of GWPS for the active tool in the
Grinding wheel peripheral speed OFF channel.
GWPSON(T number) Selection of GWPS for a non-active tool with T
Grinding wheel peripheral speed ON (T no.) number.
GWPSOF(T number) Deselection of GWPS for a non-active tool with T
Grinding wheel peripheral speed OFF (T no.) number.
S[spindle number] = value Programming of constant grinding wheel
peripheral speed.
Unit of value setting depends on basic system
(m/s or ft/s).
References:
Note
Parameter $TC_TPG1 assigns a spindle to the tool. Every following S value for this spindle
is interpreted as a grinding wheel peripheral speed when GWPS is active (see above).
If GWPS is to be selected with a new tool for a spindle for which the GWPS function is
already active, the active function must be deselected first with GWPSOF (otherwise an alarm is
given out).
GWPS can be active simultaneously for several spindles, each with a different grinding tool,
in the same channel.
Selection of GWPS with GWPSON does not automatically result in activation of tool length
compensation or of the geometry and speed monitoring functions. When GWPS is
deselected, the last speed to be calculated remains valid as the setpoint.
$P_GWPS[spindle number]
This system variable can be used to query from the sub-program whether the GWPS is
active for a specific spindle.
TRUE : GWPS programming of spindle active

FALSE : GWPS programming of spindle not active
References:
Extended Functions
17.5.3 GWPS in all operating modes
General information
This function allows the constant grinding wheel peripheral speed (GWPS) function to be
selected for a spindle immediately after POWER ON and to ensure that it remains active
after an operating mode changeover, RESET or part program end.
The function is activated via the machine data:
MD35032 $MA_SPIND_FUNC_RESET_MODE (parameterization of the GWPS function)
GWPS after POWER ON

A grinding-specific tool is defined via the following machine data:
MD20120 $MC_TOOL_RESET_VALUE
MD20130 $MC_CUTTING_EDGE_RESET_VALUE
Note
MD35032 $MA_SPIND_FUNC_RESET_MODE
If the above machine data is set and a grinding-specific tool (tool type 400 to 499, MD20110,
MD20120, MD20130) is used with reference to a valid spindle (parameter $TC_TPG1), then
GWPS is activated for that spindle.
GWPS is deselected for all other spindles in this channel.
GWPS after RESET/part program end

After a RESET/part program end, GWPS remains active for all spindles for which it was
already selected.
Note
MD35032 $MA_SPIND_FUNC_RESET_MODE
If the machine data above is set and GWPS is active on RESET or part program end, then
GWPS remains active for this spindle.
If machine data MD35032 $MA_SPIND_FUNC_RESET_MODE is not set and GWPS is
active on RESET or part program end, then GWPS is deactivated for this spindle.
GWPS is deselected for all other spindles in this channel.
It can be determined as to whether the spindle continues to rotate with the actual speed after
RESET using the following machine data:
MD35040 $MA_SPIND_ACTIVE_AFTER_RESET
Extended Functions
Programming
The spindle speed can be modified through the input of a grinding wheel peripheral speed.
The spindle speed can be modified through:
programming in the part program/overstoring
programming the grinding wheel peripheral speed through assignment to address "S" in
MDA
spindle speed control via PLC (FC18).
DB31, ... DBX84.0 (GWPS active)

The following interface signal can be used to determine whether or not the GWPS is active:
DB31, ... DBX84.0 (GWPS active)
17.5.4 Programming example for GWPS
Data of tool T1 (peripheral grinding wheel)
$TC_DP1[1,1] = 403 ;Tool type

$TC_DP3[1,1] = 300 ;Length1
$TC_DP4[1,1] = 50 ;Length2
$TC_DP12[1,1] = 0 ;Wear length 1
$TC_DP13[1.1] =0 ;Wear length 2
$TC_DP21[1.1] =300 ;Base length 1
$TC_DP22[1.1] =400 ;Base length 2
$TC_TPG1[1] = 1 ;Spindle number
$TC_TPG8[1] = 0 ;Angle of inclined wheel
$TC_TPG9[1] = 3 ;Parameter no. for radius calculation
Data of tool T5 (inclined grinding wheel)
$TC_DP1[5,1] = 401 ;Tool type

$TC_DP3[5,1] = 120 ;Length1
$TC_DP4[5,1] = 30 ;Length2
$TC_DP12[5,1] = 0 ;Wear length 1
$TC_DP13[5,1] =0 ;Wear length 2
$TC_DP21[5,1] =100 ;Base length 1
$TC_DP22[5,1] =150 ;Base length 2
$TC_TPG1[5] = 2 ;Spindle number
$TC_TPG8[5] = 45 ;Angle of inclined wheel
$TC_TPG9[5] = 3 ;Parameter no. for radius calculation
Extended Functions
Programming

N20 T1 D1 ; Select T1 and D1
N25 S1=1000 M1=3 ; 1000 rpm for spindle 1
N30 S2=1500 M2=3 ; 1500 rpm for spindle 2
...
N40 GWPSON ; ;Selection of GWPS for active tool T1
N45 S[$P_AGT[1]]=60 ; Set GWPS to 60 m/s for active tool
n=1909.85 rpm
...
N50 GWPSON(5) ; GWPS selection for tool 5 (2nd spindle)
N55 S[$TC_TPG1[5]]=40 ; Set GWPS to 40 m/s for spindle 2
n=1909.85 rpm
...
N60 GWPSOF ; Deactivate GWPS for active tool
N65 GWPSOF(5) ; Switch off GWPS for tool 5 (spindle 2)
...
For more information, see Section "P5: Oscillation - only 840D sl (Page 641)".
Supplementary references
17.6.1 Tool changes with online tool offset
Tool change
Tool changes with M6 cannot be executed in conjunction with the online tool offset function.
Extended Functions
17.7 Data lists
17.7 Data lists
17.7.1 Machine data

18094 MM_NUM_CC_TDA_PARAM Number of TDA
18096 MM_NUM_CC_TOA_PARAM Number of TOA
18100 MM_NUM_CUTTING_EDGES_IN_TOA Tool offsets per TOA

20254 ONLINE_CUTCOM_ENABLE Enable online tool radius compensation
20350 TOOL_GRIND_AUTO_TMON Automatic tool monitoring
20610 ADD_MOVE_ACCEL_RESERVE Acceleration reserve for overlaid movements

32020 JOG_VELO JOG axis velocity
35032 SPIND_FUNC_RESET_MODE Parameterization of GWPS function
17.7.2 Signals

Geometry monitoring DB31, ... .DBX83.3 DB390x.DBX2001.3
Speed monitoring DB31, ... .DBX83.6 DB390x.DBX2001.6
GWPS active DB31, ... .DBX84.1 DB390x.DBX2002.1
Extended Functions
Z2: NC/PLC interface signals 18
18.1 Digital and analog NCK I/Os (A4)
18.1.1 Signals to NC (DB10)
Overview of signals from PLC to NC
DB10 Signals to NC interface PLC NC

DBB Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Disable digital NCK inputs
Digital inputs without hardware *) (on-board inputs) **)
Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
1 Setting by PLC of the digital NCK inputs
Digital inputs without hardware *) (on-board inputs) **)
4 Disable digital NCK outputs
Digital outputs without hardware *) on-board outputs **)
Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1
5 Overwrite screen form for digital NCK outputs
6 Set value by PLC of the digital NCK outputs
7 Setting screen form for digital NCK outputs
Notes:
*) Bits 4 to 7 of the digital NCK inputs/outputs can be processed by the PLC even though there are no equivalent hardware
I/Os. These bits can therefore also be used for data exchange between the NCK and PLC.
**) The NCK digital inputs/outputs 1 to 4 are provided as onboard hardware inputs and outputs.
DB10 Signals to NC interface PLC NC
Extended Functions
Z2: NC/PLC interface signals

Extended Functions

146 Disable analog NCK inputs
147 Setting screen form for analog NCK inputs
148, 149 Setting value from PLC for analog input 1 of the NCK
166 Overwrite screen form for analog NCK outputs
167 Setting screen form for analog NCK outputs
168 Disable analog NCK outputs
170, 171 Setting value from PLC for analog output 1 of NCK
Description of signals from PLC to NC
DB10
DBB0, 122, 124, 126, Disable digital NCK inputs
128
Edge evaluation: No Signal(s) updated: Cyclic
Signal state 1 or The digital input of the NCK is disabled by the PLC. It is thus set to "0" in a defined way in the
edge change 0 1 control.
Signal state 0 or The digital input of the NCK is enabled. The signal state applied at the input can now be read
edge change 1 0 directly in the NC part program.
Corresponding to .... DB10 DBB1 (Setting by PLC of the digital NCK inputs)
DB10 DBB60 (actual value for digital NCK inputs)
Extended Functions
DB10
DBB1, 123, 125, 127, Setting by PLC of the digital NCK inputs
129
Signal state 1 or The digital NCK input is set to a defined "1" state by the PLC. This means the signal state at the
edge change 0 1 hardware input and disabling of the input (IS "Disable the digital NCK inputs") have no effect.
Signal state 0 or The signal state at the NCK input is enabled for read access by the NC part program. However, the
edge change 1 0 state can be accessed only if the NCK input is not disabled by the PLC (IS "Disable digital NCK
inputs" = 0).
Corresponding DB10 DBB0 (Disable digital NCK inputs)
to ... DB10 DBB60 (actual value for digital NCK inputs)
DB10
DBB4, 130, 134, 138, Disable digital NCK outputs
142
Signal state 1 or The digital NCK output is disabled. "0V" is output in a defined way at the hardware output.
edge change 0 1
Signal state 0 or The digital output of the NCK is enabled. As a result, the value set by the NC part program or the
edge change 1 0 PLC is output at the hardware output.
Corresponding DB10 DBB5 (Overwrite screen form for digital NCK outputs)
to ... DB10 DBB7 (Setting screen form for digital NCK outputs)
DB10 DBB6 (Setting by PLC of digital NCK outputs)
DB10
DBB5, 131, 135, 139, Overwrite screen form for digital NCK outputs
143
Signal state 1 or On signal transition 0 1 the previous NCK value is overwritten by the setting value (IS "Set value
edge change 0 1 by PLC of the digital NCK outputs"). The previous NCK value, which, for example, was directly set
by the part program, is lost.
The signal status defined by the setting value forms the new NCK value.
Signal state 0 or As the interface signal is only evaluated by the NCK on signal transition 0 1 it must be reset to "0"
edge change 1 0 again by the PLC user program in the next PLC cycle.
Special cases, Note:
errors, .... The PLC interface for the setting value (DB10, DBB6) is used both by the overwrite screen form
(for signal transition 0 1) and the setting screen form (for signal state 1). Simultaneous activation
of the two screen forms via the PLC user program must be avoided.
Corresponding to .... DB10 DBB4 (Disable digital NCK outputs)
DB10 DBB7 (Setting screen form for digital NCK outputs)
DB10 DBB6 (Setting value by PLC of digital NCK outputs)
Extended Functions
DB10
DBB6, 132, 136, 140, Set value by PLC of the digital NCK outputs
144
Signal state 1 or The signal status for the digital hardware output can be changed by the PLC with the setting value.
edge change 0 1 There are two possibilities:
With the "Overwrite screen form":
With signal transition 0 1 in the 'overwrite screen form' the PLC overwrites the previous 'NCK
value' with the 'setting value'. This is the new 'NCK value'.
With the 'setting screen form':
On signal state 1 in the "setting screen form", the "PLC value" is activated. The value used is
the 'setting value'.
With "setting value" "1", signal level 1 is put out at the hardware output. With "0", the output level is
0. The associated voltage values can be found in:
References:
Device Manual, NCU 7x0.3 PN
Signal state 0 or As the interface signal is only evaluated by the NCK on signal transition 0 1 it must be reset to
edge change 1 0 "0" again by the PLC user program in the next PLC cycle.
DB10 DBB5 (Overwrite screen form for digital NCK outputs)
DB10 DBB7 (Setting screen form for digital NCK outputs)
DB10
DBB7, 133, 137, 141, Setting screen form for digital NCK outputs
145
Signal state 1 or Instead of the NCK value, the PLC value is output at the digital hardware output. The PLC value
edge change 0 1 must first be deposited in IS "Set value by PLC of the digital NCK outputs".
The current NCK value is not lost.
Signal state 0 or The NCK value is output at the digital hardware output.
edge change 1 0
Extended Functions
DB10
DBB146 Disable analog NCK inputs
Signal state 1 or The analog input of the NCK is disabled by the PLC. It is thus set to "0" in a defined way in the
edge change 0 1 control.
Signal state 0 or The analog input of the NCK is enabled. This means that the analog value at the input can be read
edge change 1 0 directly in the NC part program if the setting screen form is set to 0 signal by the PLC for this NCK
input.
Corresponding DB10 DBB147 (Setting screen form of analog NCK inputs)
to ... DB10 DBB148 (Setting by PLC of analog NCK inputs)
DB10 DBB199 ... (Actual value of analog NCK inputs)
MD10300 $MN_FASTIO_ANA_NUM_INPUTS
DB10
DBB147 Setting screen form of analog NCK inputs
Signal state 1 or The setting value from the PLC acts as the enabled analog value
edge change 0 1 (IS "Setting value from PLC for analog NCK inputs").
Signal state 0 or The analog value at the NCK input is enabled for read access by the NC part program However,
edge change 1 0 the state can be accessed only if the NCK input is not disabled by the PLC (IS "Disable analog
NCK inputs" = 0).
Corresponding to .... DB10 DBB146 (Disable analog NCK inputs)
DB10 DBB148 to 163 (Setting by PLC of analog NCK inputs)
DB10 DBB199-209 (Actual value of analog NCK inputs)
DB10
DBB148 - 163 Setting value from PLC for analog NCK inputs
Signal state 1 or With this setting value a defined analog value can be set by the PLC. With IS "Setting screen form
edge change 0 1 of analog NCK inputs", the PLC selects whether the analog value at the hardware input or the
setting value from the PLC is to be used as the enabled analog value.
The setting value from the PLC becomes active as soon as IS "Setting screen form" is set to "1".
The setting value from the PLC is specified as a fixed point number (16 bit value including sign) in
2's complement.
DB10 DBB147 (Setting screen form of analog NCK inputs)
DB10 DBB199-209 (Actual value of analog NCK inputs)
Extended Functions
DB10
DBB166 Overwrite screen form for analog NCK outputs
Signal state 1 or On signal transition 0 1 the previous NCK value is overwritten by the setting value (IS "Setting
edge change 0 1 value from PLC for analog NCK outputs"). The previous NCK value which, for example, was
directly set by the part program, is lost.
The analog value specified by the PLC setting value forms the new NCK value.
errors, .... The PLC interface for the setting value is used both by the overwrite screen form (for signal
transition 0 1) and the setting screen form (for signal state 1). Simultaneous activation of the two
screen forms must be avoided via the PLC user program.
Corresponding to .... DB10 DBB168 (Disable analog NCK outputs)
DB10 DBB170-185 (Setting by PLC of analog NCK outputs)
MD10310 $MN_FASTIO_ANA_NUM_OUTPUTS
DB10
DBB167 Setting screen form of analog NCK outputs
Signal state 1 or Instead of the NCK value, the PLC value is output at the analog hardware output. The PLC value
edge change 0 1 must first be stored in IS "Setting value from PLC for the analog NCK outputs".
The current NCK value is not lost.
Signal state 0 or The NCK value is output at the analog hardware output.
edge change 1 0
DB10 DBB166 (Overwrite screen form of analog NCK outputs)
Extended Functions
DB10
DBB168 Disable analog NCK outputs
Signal state 1 or The analog output of the NCK is disabled. "0V" is output in a defined way at the hardware output.
edge change 0 1
Signal state 0 or The analog output of the NCK is enabled. As a result, the value set by the NC part program or the
edge change 1 0 PLC is output at the hardware output.
Corresponding to .... DB10 DBB166 (Overwrite screen form of analog NCK outputs)
DB10
DBB170 - 185 Setting value from PLC for analog NCK outputs
Signal state 1 or With this setting value, the value for the analog hardware output can be changed by the PLC.
edge change 0 1 There are two possibilities:
With the "Overwrite screen form":
With signal transition 0 1 in the 'overwrite screen form' the PLC overwrites the previous 'NCK
value' with the 'setting value'. This is the new "NCK value".
With the "setting screen form":
On signal state 1 in the "setting screen form", the "PLC value" is activated. The value used is
the 'setting value'.
The setting value from the PLC is specified as a fixed point number (16 bit value including sign) in
2's complement.
DB10 DBB166 (Overwrite screen form of analog NCK outputs)
Extended Functions
18.1.2 Signals from NC (DB10)
Overview of signals from NC to PLC
DB10 Signals from NC interface NC PLC

60 Actual value for digital NCK inputs
(on-board inputs) **)
Input 4 Input 3 Input 2 Input 1
64 Setpoint for digital NCK outputs
Digital inputs without hardware *) on-board outputs **)
Output Output 15 Output 14 Output 13 Output 12 Output 11 Output 10 Output 9
16
24
32
40
Notes:
*) Bits 4 to 7 of the digital inputs and NCK outputs can be processed by the PLC although no
equivalent hardware I/Os exist. These bits can therefore also be used for data exchange between the
NCK and PLC.
**) The NCK digital inputs/outputs 1 to 4 are provided as onboard hardware inputs and outputs.
DB10 Signals from NC interface NC PLC
194, Actual value for analog input 1 of NCK
195
197
199
Extended Functions

201
203
205
207
209
210, Setpoint for analog output 1 of NCK
211
213
215
217
219
221
223
225
Description of signals from NC to PLC
DB10
DBB60, 186 - 189 Actual value for digital NCK inputs
Signal state 1 or Signal level "1" is active at the digital hardware input of the NCK.
edge change 0 1
Signal state 0 or Signal level "0" is active at the digital hardware input of the NCK.
edge change 1 0
Special cases, The influence of interface signal:
errors, ...... DB10 DBB0 (Disable digital NCK inputs)
is ignored for the actual value.
Corresponding to .... DB10 DBB0 (Disable digital NCK inputs)
Extended Functions
DB10
DBB64, 190 - 193 Setpoint for digital NCK outputs
Signal state 1 or The NCK value for the digital output currently set (setpoint) is "1".
edge change 0 1
Signal state 0 or The NCK value for the digital output currently set (setpoint) is "0".
edge change 1 0
Signal irrelevant for This 'setpoint' is only output to the hardware output under the following conditions:
...
Output is not disabled (IS "Disable digital NCK outputs")
PLC has switched to the NCK value (IS "Setting screen form for digital NCK inputs")
As soon as these conditions are fulfilled, the "setpoint" of the digital output corresponds to the
"actual value".
DB10 DBB7 (Setting mask for digital NCK outputs)
DB10
DBB194 - 209 Actual value for analog NCK inputs
Signal state 1 or The analog value applied to the analog NCK input is signalled to the PLC.
edge change 0 1 The actual value is set as a fixed point number (16 bit value including sign) in 2's complement by
the NCK.
Signal state 0 or The effect of the PLC on the analog value (e.g. with IS "Disable analog NCK inputs") is ignored.
edge change 1 0
DB10 DBB147 (Setting screen form of analog NCK inputs)
DB10 DBB148-163 (Setting by PLC of analog NCK inputs)
DB10
DBB210 - 225 Setpoint for analog NCK outputs
Signal state 1 or The current set NCK value for the analog output (setpoint) is signalled to the PLC.
edge change 0 1 The set value is set as a fixed point number (16 bit value including sign) in 2's complement by the
NCK.
Extended Functions
18.2 Distributed systems (B3)
DB10
DBB210 - 225 Setpoint for analog NCK outputs
Signal state 0 or This 'setpoint' is only output to the hardware output under the following conditions:
edge change 1 0
Output is not disabled (IS "Disable analog NCK outputs")
The PLC has switched to the NCK value (IS "Setting screen form of analog NCK outputs")
Corresponding DB10 DBB168 (Disable analog NCK outputs)
to .... DB10 DBB166 (Overwrite screen form of analog NCK outputs)
18.2.1 Defined logical functions/defines
BUSTYP
Name Value Interface DB19 Meaning

MPI 1 DBW100.102.104. Control unit to MPI, 187.5 kbaud
120. 130
Bits 8 -15
OPI 2 " Control unit to MPI, 1.5 Mbaud
STATUS

OFFL_REQ_PLC 1 Online interfaces PLC to control unit: PLC wants to displace control unit by
1. : DBB124 offline request.
2. : DBB134
OFFL_CONF_PLC 2 Online interfaces Control unit to PLC: Acknowledgement of OFFL_REQ_PLC
1. : DBB124 The meaning of the signal is dependent on Z_INFO DBB125
2. : DBB134 or DBB135
OFFL_REQ_OP 3 Online interfaces Control unit to PLC: Control unit would like to go offline from
1. : DBB124 this NCU and outputs an offline request
2. : DBB134
OFFL_CONF_OP 4 Online interfaces PLC to control unit: Acknowledgement of OFFL_REQ_OP
2. : DBB134 or DBB135
Extended Functions

ONL_PERM 5 Online request PLC to control unit: PLC notifies control unit as to whether it
interface can go online or not.
DBB108 The meaning of the signal is dependent on Z_INFO: DBB109
S_ACT 6 Online interfaces Control unit to PLC: Control unit goes online or changes
1. : DBB124 operating focus.
or DBB135
OFFL_REQ_FOC 7 Online interfaces Control unit to PLC: Control unit would like to take operating
1. : DBB124 focus away from this NCU
2. : DBB134
OFFL_CONF_FOC 8 Online interfaces PLC to control unit: Acknowledgement of OFFL_REQ_FOC
2. : DBB134 or DBB135
ONL_REQ_FOC 9 Online interfaces Control unit to PLC: Control unit would like to set operating
1. : DBB124 focus to this NCU
2. : DBB134
ONL_PERM_FOC 10 Online interfaces PLC to control unit: Acknowledgement of ONL_REQ_FOC
2. : DBB134 or DBB135
Z_INFO

DISC_FOC 9 DBB125 Control unit switches operating focus to another NCU.
DBB135
Set 10 DBB109 Bit 0-3 Positive acknowledgement
DBB125
DBB135
CONNECT 11 DBB125 Control unit has gone online on this NCU.
DBB135
MMC_LOCKED 13 DBB109 Bit 0-3 HMI has set switchover disable.
DBB125 There are processes running on this control unit that may not
DBB135 be interrupted by a switchover.
PLC_LOCKED 14 DBB109 Bit 0-3 The HMI switchover disable is set in the HMI-PLC interface.
DBB125 Control unit cannot go offline from this NCU or change
operating focus.
DBB135
PRIO_H 15 DBB109 Bit 0-3 Control units with a higher priority are operating on this NCU.
DBB125 Requesting control unit cannot go online to this NCU.
DBB135
Extended Functions
STATUS and Z_INFO can be combined as follows
Name: Status Z_INFO Meaning

OFFL_REQ_PLC Set PLC wants to displace online control unit by offline request.
OFFL_CONF_PLC Set Control unit positively acknowledges the offline request from PLC.
Control unit will subsequently go offline.
OFFL_CONF_PLC MMC_LOCKED Control unit negatively acknowledges the offline request.
Control unit will not go offline, as processes are running that must
not be interrupted.
OFFL_REQ_OP Set Control unit would like to go offline from the online NCU and outputs
an offline request.
OFFL_CONF_OP Set PLC positively acknowledges the offline request.
Control unit will subsequently go offline from this NCU.
OFFL_CONF_OP PLC_LOCKED PLC negatively acknowledges the offline request from control unit.
User has set the HMI switchover disable, control unit cannot go
offline, MMCx_SHIFT_LOCK = TRUE, x=1 or 2, 1st or 2nd HMI-PLC
interface.
ONL_PERM No. of HMI-PLC online PLC issues the online enabling command to the requesting control
interface, OK unit. Control unit can then go online to this NCU. Content of Z_INFO:
Bit 0 ..3: Set
Bit 4... 7: No. of HMI-PLC online interface with which the control unit
should connect:
First HMI-PLC online interface
Second HMI-PLC online interface
ONL_PERM MMC_LOCKED The requesting control unit cannot go online.
Two control units on which uninterruptible processes are in progress
are connected online to this NCU. The PLC cannot suppress either
of the two control units.
ONL_PERM PLC_LOCKED The requesting control unit cannot go online.
User has set HMI switchover disable, MMCx_SHIFT_LOCK = TRUE,
x=1 or 2, first or second HMI online interface.
ONL_PERM PRIO_H The requesting control unit cannot go online.
Two control units that are both higher priority than the requesting
control unit are connected online to the NCU.
The PLC cannot suppress either of the two control units.
S_ACT CONNECT The requesting control unit has gone online.
The PLC now activates HMI sign-of-life monitoring.
S_ACT DISC_FOCUS Server HMI has disconnected the operating focus from this NCU.
OFFL_REQ_FOC Set Server HMI would like to disconnect the operating focus from this
NCU and outputs an offline focus request.
OFFL_CONF_FOC Set PLC positively acknowledges the offline focus request.
Server HMI can disconnect operating focus.
OFFL_CONF_FOC PLC_LOCKED PLC negatively acknowledges the online focus request.
User has set HMI switchover disable, server HMI cannot disconnect
operating focus, MMCx_SHIFT_LOCK = TRUE,
x=1 or 2, first or second HMI-PLC interface.
Extended Functions
Name: Status Z_INFO Meaning

ONL_REQ_FOC Set Server HMI would like to set the operating focus on this NCU and
outputs an online focus request.
ONL_PERM_FOC Set PLC positively acknowledges the online focus request.
Server HMI then connects operating focus to this NCU.
ONL_PERM_FOC PLC_LOCKED PLC negatively acknowledges the online focus request. User has set
HMI switchover disable, server HMI cannot set operating focus,
MMCx_SHIFT_LOCK = TRUE,
x=1 or 2, first or second HMI-PLC interface.
18.2.2 Interfaces in DB19 for M:N

The HMI/PLC interface in DB19 is divided into three areas.
Online request interface

The online request sequence is executed on this interface if a control unit wants to go online.
HMI writes its client ID to ONL_REQUEST and waits for the return of the client ID in
ONL_CONFIRM.
After the positive acknowledgement from the PLC, the control unit sends its parameters and
waits for online permission (in PAR_STATUS, PAR_Z_INFO).
HMI parameter transfer:
Client identification -> PAR_CLIENT_IDENT
HMI type -> PAR_MMC_TYP
MCP address -> PAR_MSTT_ADR
With the positive online permission, the PLC also sends the number of the HMI-PLC online
interface DBB109.4-7 to be used by the control unit.
The MMC then goes online and occupies the online interface assigned by the PLC.
Online interfaces
Two control units can be connected online to one NCU at the same time.
The online interface is available for each of the two online control units separately.
After a successful online request sequence, the control unit receives the number of its online
interface from the PLC.
The HMI parameters are then transferred to the corresponding online interface by the PLC.
The control unit goes online and occupies its own online interface via which data are then
exchanged between the HMI and PLC.
Extended Functions
HMI data interfaces

User data from/to the HMI are defined on these:
DBB 0-49 control unit 1 interface
DBB 50-99 control unit 2 interface
These data and signals are always needed to operate control units.
M:N sign-of-life monitoring

This is an additional monitoring function which must not be confused with the HMI sign-of-life
monitor. For further information, please refer to the relevant signals.
In certain operating states, control units with activated M:N switchover (parameterizable in
NETNAMES.INI) must be capable of determining from a PLC data whether they need to wait
or not before linking up with an NCU.
Example:
Control units with an activated control unit switchover function must be capable of starting up
an NCU without issuing an online request first.
Control unit must go online for service-related reasons.
The operation is coordinated in the online request interface via data DBW110:
M_TO_N_ALIVE
The M:N sign of life is a ring counter which is incremented cyclically by the PLC or set to a
value of 1 when it overflows.
Before a control unit issues an online request, it must check the sign of life to establish
whether the M:N switchover is activated in the PLC.
Procedure:
HMI reads the sign of life at instants T0 and T0 + 1.
Case 1: negative acknowledgement for reading process, DB19 does not exist. Control unit
goes online without request procedure.
Case 2: m_to_n_alive = 0, control unit switchover disabled. Control unit goes online without
request procedure.
Case 3: m_to_n_alive (T0) = m_to_n_alive (T0+1), control unit switchover disabled. Control
unit goes online without request procedure.
Case 4: m_to_n_alive (T0) <> m_to_n_alive (T0+1), control unit switchover enabled.
Case 1 ... case 3 apply only under special conditions and not in normal operation.
Extended Functions
Online request interface
DB19 DBW100 ONL_REQUEST

Client_Ident Control unit would like to go online and use the online request interface. HMI first
writes its Client_Ident as a request.
Bit 8 .. 15: Bus type: MPI 1 or BTSS 2
Bit 0 .. 7: HMI bus address
DB19 DBW102 ONL_CONFIRM.
Client_Ident If the online request interface is not being used by another control unit, the PLC
returns the Client identification as positive acknowledgement.
Bit 8 .. 15: Bus type: MPI 1 or BTSS 2
DB19 DBW104 PAR_CLIENT_IDENT HMI parameter transfer to PLC
Client_Ident Bit 8 .. 15: Bus type: MPI 1 or BTSS 2
DB19 DBB106 PAR_MMC_TYP HMI parameter transfer to PLC
HMI type from NETNAMES.INI Type properties of the control unit configured in file NETNAMES.INI. Evaluated
by the PLC when MMC is suppressed (server, main/secondary operator panel,
...), see description of file NETNAMES.INI
DB19 DBB107 PAR_MSTT_ADR HMI parameter transfer to PLC
MCP address from NETNAMES.INI Address of MCP to be switched over or activated/deactivated with the control
unit.
Parameter from NETNAMES.INI
255 No MCP is assigned to control unit, no MCP will be activated/deactivated
DB19 DB108 PAR_STATUS PLC sends HMI pos./neg. online permission
ONL_PERM (5) PLC notifies HMI as to whether control unit can go online or not. The meaning of
the signal is dependent on PAR_Z_INFO:
DB19 DBB109 PAR_Z_INFO PLC sends HMI pos./neg. online permission
No. of HMI-PLC online interface, OK PLC issues the online enabling command to the requesting control unit.
(10) Control unit can then go online to this NCU.
Bit 0 ..3: Set
Bit 4 .. 7: No. of HMI-PLC online interface with which the control unit should
connect:
First HMI-PLC online interface
Second HMI-PLC online interface
MMC_LOCKED (13) The requesting control unit cannot go online. Two control units on which
uninterruptible processes are in progress are connected online to this NCU. The
PLC cannot suppress either of the two control units.
PLC_LOCKED (14) The control unit switchover disable is set in the HMI-PLC interface.
PRIO_H (15) The requesting control unit cannot go online. Two control units that are both
higher priority than the requesting control unit are connected online to the NCU.
The PLC cannot suppress either of the two control units.
Extended Functions
Sign of life of M:N switchover
DB19 DBW110 M_TO_N_ALIVE

1 ... 65535 Ring counter that is cyclically incremented by the PLC. Indicator for the HMI that
the M:N switchover is active and ready.
1. HMI/PLC online interface
DB19 DBW120 MMC1_CLIENT_IDENT

refer to PAR_CLIENT_IDENT
after issuing positive online permission, the PLC transfers the HMI parameters to
the online interface PAR_CLIENT_IDENT -> MMC1_CLIENT_IDENT
DB19 DBB122 MMC1_TYP
refer to PAR_MMC_TYP
After issuing positive online permission, the PLC transfers the HMI parameters to
the online interface PAR_MMC_TYP -> MMC1_TYP
DB19 DBB123 MMC1_MSTT_ADR
refer to PAR_ MSTT_ADR
After issuing positive online permission, the PLC transfers the HMI parameters to
the online interface PAR_ MSTT_ADR -> MMC1_MSTT_ADR
DB19 DBB124 MMC1_STATUS
Requests from online HMI to PLC or vice-versa. The meaning of the signal is
dependent on MMC1_Z_INFO
OFFL_REQ_PLC (1) PLC to HMI: PLC wants to displace control unit by offline request.
OFFL_CONF_PLC (2) HMI to PLC: Acknowledgement of OFFL_REQ_PLC
OFFL_REQ_OP (3) HMI to PLC: Control unit would like to go offline from this NCU and outputs an
offline request
OFFL_CONF_OP (4) PLC to HMI: Acknowledgement of OFFL_REQ_OP
S_ACT (6) HMI to PLC: Control unit goes online or changes operating focus
OFFL_REQ_FOC (7) HMI to PLC: Control unit would like to take operating focus away from this NCU
OFFL_CONF_FOC (8) PLC to HMI: Acknowledgement of OFFL_REQ_FOC
ONL_REQ_FOC (9) HMI to PLC: Control unit would like to set operating focus to this NCU
ONL_PERM_FOC (10) PLC to HMI: Acknowledgement of ONL_REQ_FOC
DB19 DBB125 MMC1_Z_INFO
Request from online HMI to PLC or vice-versa. The meaning of the signal is
dependent on MMC1_STATUS
DISC_FOC (9) Control unit switches operating focus to another NCU.
OK (10) Positive acknowledgement
CONNECT (11) Control unit has gone online on this NCU.
PLC_LOCKED (14) The control unit switchover disable is set in the HMI-PLC interface. Control unit
cannot go offline from this NCU or change operating focus.
PRIO_H (15) Control units with a higher priority are operating on this NCU. Requesting control
unit cannot go online to this NCU
Extended Functions
Bit signals
DB19 MMC1_SHIFT_LOCK
DBX 126.0 Disable/enable control unit switchover
Data Block
Signal state 1 or Control unit switchover or change in operating focus is disabled.
edge change The current control unit-NCU constellation remains unchanged.
01
Signal state 0 or Control unit switchover or change in operating focus is enabled
edge change
10
DB19 MMC1_MSTT_SHIFT_LOCK
DBX 126.1 Disable/enable MCP switchover
Data Block
Signal state 1 or MCP switchover is disabled.
edge change The current MCP-NCU constellation remains unchanged.
01
Signal state 0 or MCP switchover is enabled
edge change
10
DB19 MMC1_ACTIVE_REQ
DBX 126.2 Control unit 1 requests active operating mode
Data Block
Signal state 1 or HMI to PLC: passive control unit 1 requests active operating mode
edge change
01
Signal state 0 or PLC to HMI: Request received
edge change
10
Extended Functions
DB19 MMC1_ACTIVE_PERM
DBX 126.3 Active/passive operating mode
Data Block
Signal state 1 or PLC to HMI:
edge change passive operator unit 1 can change to active operating mode
01
Signal state 0 or PLC to HMI:
edge change active operator panel must change to passive operating mode
10
DB19 MMC1_ACTIVE_CHANGED
DBX 126.4 Active/passive operating mode of HMI
Data Block
Signal state 1 or HMI to PLC:
edge change Control unit has completed changeover from passive to active mode
01
Signal state 0 or HMI to PLC:
edge change Control unit has completed changeover from active to passive mode
10
DB19 MMC1_CHANGE_DENIED
DBX126.5 Operating mode changeover rejected
Data Block
Signal state 1 or HMI to PLC or PLC to HMI depending on status of interface:
edge change Operating mode cannot be changed due to uninterruptible processes on active control unit.
01
Signal state 0 or HMI to PLC or PLC to HMI depending on status of interface:
edge change Acknowledgement on MMC1_CHANGE_DENIED (FALSE TRUE)
10
Extended Functions
2. HMI/PLC online interface

The signals of the 2nd HMI/PLC online interface are analogous in meaning to the signals of
the 1st HMI/PLC online interface (MMC2_ ... replaces MMC1_...)..
Sign-of-life monitoring HMI

After a control unit has gone online to an NCU, the HMI sign of life is set in the interface.
(E_BTSSReady, E_MMCMPI_Ready, E_MMC2Ready)
The signals are automatically set by the HMI when the control unit goes online and stay set
for as long as it remains online.
They are provided separately for each HMI/PLC interface and used by the PLC to monitor
the HMI sign of life.
First HMI/PLC online interface
A distinction between an control unit link via the OPI (1.5 Mbaud) or the MPI (187.5 kbaud) is
made on this interface.
The signal corresponding to the bus type is set while the control unit is online.
DB10 DBX104.0 MCP1 ready

FALSE MCP1 is not ready
TRUE MCP1 is ready
DB10 DBX104.1 MCP2 ready
FALSE MCP2 is not ready
TRUE MCP2 is ready
DB10 DBX104.2 HHU ready
FALSE HHU is not ready
TRUE HHU is ready
DB10 DBX108.3 E_MMCBTSSReady
FALSE No control unit online to OPI
TRUE Control unit online to OPI
DB10 DBX108.2 E_MMCMPIReady
FALSE No control unit online to MPI
TRUE Control unit online to MPI
Extended Functions
Second HMI/PLC online interface

This interface utilizes a group signal for both bus types. No distinction is made between OPI
and MPI.
DB10 DBX108.1 E_MMC2Ready

FALSE no control unit online to OPI or MPI
TRUE Control unit online to OPI or MPI
The sign-of-life monitor is switched on by the PLC as soon as a control unit has gone online
to its interface and switched off again when it goes offline.
Sign-of-life monitoring will be enabled:
as soon as control unit or HMI logs on online to its HMI/PLC interface with
S_ACT/CONNECT.
Sign-of-life monitoring will be disabled:
as soon as control unit goes offline.
1. HMI wants to switchover and log off from PLC with OFFL_REQ_OP/OK
2. PLC acknowledges to HMI with OFFL_CONF_OP/OK
3. Control unit or HMI will be displaced by PLC with OFFL_REQ_PLC/OK
HMI acknowledges to PLC with OFFL_CONF_PLC/OK
In both instances the PLC detects that a control unit is going offline and waits for the TRUE-
FALSE edge of its HMI sign-of-life signal.
The PLC then ceases to monitor the sign-of-life signal.
DB10
DBX107.6 NCU link active
Edge evaluation: Signal(s) updated:
Signal state 1 or edge NCU link communication is active.
change 0 1
Signal state 0 or edge No NCU link communication is active.
change 1 0
Signal irrelevant for ... System with an NCU.
References Device Manual, NCU 7x0.3 PN
Extended Functions
18.2.4 Signals from axis/spindle (DB31, ...)
DB31, ...
DBX60.1 NCU link axis active
Signal state 1 or edge Axis is active as NCU link axis.
change 0 1
Signal state 0 or edge Axis is used as a local axis.
change 1 0
Signal irrelevant for ... System with an NCU.
Additional references NCU 7x0.3 PN Manual
DB31, ...
DBX61.2 Axis ready
Meaning The signal is routed on the NCU in the NCU link group to which the axis is physically
connected.
Signal state 1 or edge Axis is ready.
change 0 1
Signal state 0 or edge Axis is not ready.
change 1 0 This status will be set when the channel, the operating modes group or the NCK have
generated the alarm "not ready".
DB31, ...
DBX62.7 Axis container rotation active
Signal state 1 or edge An axis container rotation is active for the axis.
change 0 1
Signal state 0 or edge An axis container rotation is not active for the axis.
change 1 0
Extended Functions
18.3 Manual and Handwheel Travel (H1)
DB10
DBB97, 98, 99 Channel number geometry axis for handwheel 1, 2, 3
Significance of signal The operator can assign an axis to the handwheel (1, 2, 3) directly on the operator panel front. If
this axis is a geometry axis (IS "Machine axis" = 0), the assigned channel number for the
handwheel in question is transferred to the PLC.
In this way, the IS "Activate handwheel" is set for the selected geometry axis in accordance with
the state set by the operator (IS "Handwheel selected").
The following codes apply to the channel number:
Bit Channel number
7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 -
0 0 0 0 0 0 0 1 1
0 0 0 0 0 0 1 0 2
With machine axes (IS "Machine axis" = 1), the IS "Channel number geometry axis for handwheel
1, 2, 3" has no meaning.
For further information, see IS "Axis number for handwheel 1, 2, 3".
Corresponding to .... DB10 DBB100 ff (axis number for handwheel 1, 2, 3)
DB10 DBX100.6 ff (handwheel selected)
DB10 DBX100.7 ff (machine axis)
DB21, ... DBX12.0 - 12.2 ff (activate handwheel)
Application If DB10 DBB97 = 2, then handwheel 1 is assigned to channel 2.
example(s)
Extended Functions
DB10
DBB100, 101, 102
Bit 0 - 4 Axis number for handwheel 1, 2 or 3
Edge evaluation: no Signal(s) updated: Cyclic
Significance of signal The operator can assign an axis to every handwheel directly via the operator panel front. To do so,
he defines the required axis (e.g. X). The basic PLC program provides the number of the axis plus
the information "machine axis or geometry axis" (IS "machine axis") as HMI interface signals. The
basic PLC program sets the interface signal "Activate handwheel" for the defined axis. Depending
on the setting in the HMI interface signal "machine axis", either the interface for the geometry axis
or for the machine axis is used.
The following must be noted when assigning the axis designation to the axis number:
NST "machine axis" = 1; e.g. machine axis:
The assignment is done via the machine data:
MD10000 $MN_AXCONF_MACHAX_NAME_TAB[n] (machine axis name).
NST "machine axis" = 0; e.g. geometry axis:
The assignment is done via the machine data:
MD20060 $MC_AXCONF_GEOAX_NAME_TAB[n] (geometry axis name in channel)
With the NST "Channel number geometry axis handwheel n" the channel number assigned to the
handwheel is defined.
For following codes are used for the axis number:
Bit Axis number
4 3 2 1 0
0 0 0 0 0
0 0 0 0 1 1
0 0 0 1 0 2
0 0 0 1 1 3
0 0 1 0 0 4
0 0 1 0 1 5
0 0 1 1 0 6
0 0 1 1 1 7
0 1 0 0 0 8
Corresponding to .... DB10 DBX97 ff (Channel number geometry axis handwheel n)
DB10 DBX100.6 ff (handwheel selected)
DB21, ... DBX12.0 to DBX12.2 ff (activate handwheel)
DB31, ... DBX4.0 to DBX4.2 (activate handwheel)
MD10000 $MN_AXCONF_MACHAX_NAME_TAB [n] (machine axis name)
MD20060 $MC_AXCONF_GEOAX_NAME_TAB [n] (geometry axis in the channel)
Extended Functions
DB10
DBX100.6, 101.6,
102.6 Handwheel selected (for handwheel 1, 2 or 3)
Signal state 1 or The operator has selected the handwheel for the defined axis via the operator panel front (i.e.
edge change 0 1 activated). This information is made available by the basic PLC program at the HMI interface.
The basic PLC program sets the interface signal:
DB21, ... DBX12.0-12.2 ff (Activate handwheel)
for the defined axis to "1".
The associated axis is also displayed at the HMI interface:
and
DB10 DBB100 ff (axis number for handwheel 1).
As soon as the handwheel is active, the axis can be traversed in JOG mode with the handwheel
(DB21, ... DBX40.0-40.2 ff (Handwheel active).
Signal state 0 or The operator has disabled the handwheel for the defined axis via the operator panel front. This
edge change 1 0 information is made available by the basic PLC program at the HMI interface.
The basic PLC program can set the interface signal:
DB21, ... DBX12.0-12.2 ff (Activate handwheel)
for the defined axis to "0".
Corresponding to .... DB10 DBB100 ff (axis number)
DB21, ... DBX12.0-12.2 ff (activate handwheel)
DB21, ... DBX40.0 - DBX40.2 ff (handwheel active)
DB31, ... DBX4.0 - DBX4.2 (activate handwheel)
DB10 DBB97 ff (channel number geometry axis for handwheel 1, 2 or 3)
DB10
DBX100.7, 101.7,
102.7 Machine axis (for handwheel 1, 2 or 3)
Signal state 1 or The operator has assigned an axis to the handwheel (1, 2, 3) directly on the operator panel front.
edge change 0 1 This axis is a machine axis.
For further information see IS "Axis number".
Signal state 0 or The operator has assigned an axis to the handwheel (1, 2, 3) directly on the operator panel front.
edge change 1 0 This axis is a geometry axis.
For further information see IS "Axis number".
Corresponding DB10 DBB100 ff (axis number)
to .... DB10 DBX100.6 ff (handwheel selected)
DB10 DBB97 ff (channel number geometry axis for handwheel 1, 2 or 3)
Extended Functions
18.3.2 Signals to channel (DB21, ...)
Overview of signals to channel (to NCK)
DB21, ...
DBX0.3 Activate DRF
Edge evaluation: No Signal(s) updated: Cyclically
Signal state 1 Request to activate the DRF function.
With the DRF function, the DRF offset can be changed in the AUTOMATIC and MDI modes using a
handwheel.
Signal state 0 No request of the DRF function.
Signal irrelevant for JOG mode
...
Corresponding to ... DB21, ... DBX24.3 (DRF selected)
DB21, ...
DBX12.0-2,
DBX16.0-2,
DBX20.0-2 Handwheel assignment for geometry axis (1, 2, 3)
Signal state <> 0 Request for activation of the appropriate geometry axis handwheel.
The interface can be interpreted either bit or binary-coded. The selection is defined using machine
data:
Bit-coded: Maximum of three handwheels
Note
At any one time, the axis can only be assigned to one handwheel. If several interface signals are
set simultaneously, then the following priority applies: "Handwheel 1" before "handwheel 2" before
"handwheel 3"
Number of the assigned handwheel Bit 2 Bit 1 Bit 0
1 0 0 1
2 0 1 0
3 1 0 0
Binary-coded: Maximum of six handwheels
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
Signal state 0 No request for activation of a handwheel.
Corresponding to ... DB21, ... DBX40.6-7 ff (handwheel active for geometry axis)
Extended Functions
DB21, ...
DBX12.4,
DBX16.4,
DBX20.4 Traversing key disable for geometry axis (1, 2, 3)
Signal state 1 A traversing request using the "Plus" and "Minus" traversing keys is ignored for the geometry axis.
If the traversing key disable is activated while traversing, then traversing is canceled.
Signal state 0 The plus and minus traversing keys are enabled.
Application It is thus possible, depending on the operating mode, to disable manual traversing of the geometry
example(s) axis in JOG mode with the traversing keys from the PLC user program.
Corresponding to ... DB21, ... DBX12.6-7 ff (traversing key plus or traversing key minus for geometry axis)
DB21, ...
DBX12.5,
DBX16.5,
DBX20.5 Rapid traverse override for geometry axis (1, 2, 3)
Signal state 1 Moves the axis due to a traversing request:
DB21, ... DBX12.7 == 1 (traversing key plus)
DB21, ... DBX12.6 == 1 (traversing key minus)
when the interface signal is set, the geometry axis is moved with rapid traverse.
The rapid traverse feedrate is defined in machine data:
MD32010 $MA_JOG_VELO_RAPID (conventional rapid traverse)
The rapid traverse override is effective in JOG mode for:
Continuous travel
Incremental travel (INC1, INC10, ...)
The rapid traverse velocity can be influenced using the rapid traverse override switch.
Signal state 0 The geometry axis traverses with the defined JOG velocity:
SD41110 $SN_JOG_SET_VELO (axis velocity with JOG)
or
MD32020 $MA_JOG_VELO (conventional axis velocity).
Signal irrelevant for Operating modes AUTOMATIC and MDI
...
Reference point approach (JOG mode)
Corresponding to ... DB21, ... DBX12.6-7 ff (traversing key plus and traversing key minus for geometry axis)
Further references Function Manual, Basic Function; Feedrates (V1)
Extended Functions
DB21, ...
DBX12.6-7,
DBX16.6-7,
DBX20.6-7 Plus and minus traversing keys for geometry axis (1, 2, 3)
Signal state 1 The selected geometry axis can be traversed in both directions in JOG mode with the traversing
keys plus and minus.
Depending on the active machine function as well as the setting "JOG or Continuous mode":
SD41050 $SN_JOG_CONT_MODE_LEVELTRIGGRD (JOG/Cont. mode continuous with JOG)
and
MD11300 $MN_JOG_INC_MODE_LEVELTRIGGRD (INC and REF in JOG mode)
different reactions are triggered on a signal change.
1. Continuous traversing with JOG mode
The geometry axis traverses in the direction concerned as long as the interface signal
is set to 1 (and as long as the axis position has not reached an activated limitation).
2. Continuous traversing with Continuous mode
On the first edge change 0 1, the geometry axis starts to traverse in the relevant direction.
This traversing movement still continues when the edge changes from 1 0. Any new edge
change 0 1 (same traversing direction!) stops the traversing movement.
3. Incremental traversing with JOG mode
With signal 1 the geometry axis starts to traverse at the set increment. If the signal changes to
the 0 state before the increment is traversed, the traversing movement is interrupted. When the
signal state changes to 1 again, the movement is continued. The geometry axis can be stopped
and started several times as described above until it has traversed the complete increment.
4. Incremental traversing with Continuous mode
On the first edge change 0 1 the geometry axis starts to traverse at the set increment. If
another edge change 0 1 is performed with the same traverse signal before the geometry
axis has traversed the increment, the traversing movement will be cancelled. The increment
traversing will then not be completed.
Note
If both traversing signals (plus and minus) are set at the same time there is no traversing or the
current traversing is aborted.
In contrast to machine axes, for geometry axes, only one geometry axis can be traversed at
any one time using the traversing keys.
Traversing by means of the traversing keys can be locked via DBX12.4 = 1 ff. (traversing key
disable).
Signal state 0 See cases 1 to 4 above.
Signal irrelevant for Operating modes AUTOMATIC and MDI
...
Special cases, The geometry axis cannot be traversed in JOG mode:
errors, ....
If it is already being traversed via the axial PLC interface (as a machine axis).
If another geometry axis is already being traversed with the traversing keys.
Alarm 20062 "Axis already active" is output.
Corresponding to ... DB31, ... DBX8.7 or DBX8.6 (traversing keys plus and minus for machine axes)
DB21, ... DBX12.4 ff (traversing key disable for geometry axes)
Extended Functions
DB21, ...
DBX13.0-5,
DBX17.0-5,
DBX21.0-5 Request for incremental machine function for geometry axis (1, 2, 3)
Signal state 1 Request for a machine function for incremental traversing of the geometry axis in JOG mode:
Bit 0 = INC1
Bit 1 = INC10
Bit 2 = INC100
Bit 3 = INC1000
Bit 4 = INC10000
Bit 5 = INCvar
An increment corresponds to an actuation of one of the "plus" and "minus" traversing keys, or a
detent position of the active handwheel. Specification of the increment sizes via:
INC1 to INC10000:
MD11330 $MN_JOG_INCR_SIZE_TAB (increment size for INC/handwheel)
INCvar:
Note
If several requests are set simultaneously, no machine function becomes active.
Signal state 0 No machine function is requested.
If a geometry axis is currently being traversed via a machine function, the movement is aborted
through deselection or change of the machine function.
Corresponding to ... DB21, ... DBB41 ff (active machine function INC1,...) for geometry axes
DB21, ... DBX13 ff (machine function continuous) for geometry axes
DB21, ...
DBX13.6,
DBX17.6,
DBX21.6 Request for continuous machine function for geometry axis (1, 2, 3)
Signal state 1 The machine function for continuous traversing of the geometry axis in JOG mode with the
traversing keys "Plus" and "Minus" is requested.
Signal state 0 Machine function "Continuous traversing" is not requested.
Corresponding to ... DB21, ... DBB41.6 ff (active continuous machine function)
Extended Functions
DB21, ...
DBX15.0,
DBX 19.0,
DBX 23.0 Handwheel direction of rotation inversion for geometry axis (1, 2, 3)
Signal state 1 Request to invert the handwheel direction of rotation.
It is only permissible to change the interface signal when the geometry axis is at a standstill.
Signal state 0 The handwheel direction of rotation to which geometry axis 1, 2 or 3 is assigned, is not inverted.
Application The handwheel direction of movement does not match the expected direction of the axis.
example(s)
A handwheel (HT2, HT8) has been assigned to various axes.
Corresponding to ... DB21, ... DBX43.0, 49.0, 55.0 (handwheel direction of rotation inversion active for geometry axis 1,
2, 3)
DB21, ...
DBX30.0-2 Activate contour handwheel
Signal state 1 Request for activation of the corresponding handwheel for the "Contour handwheel / path
specification with handwheel" function.
The interface can be interpreted either bit or binary-coded. The specification is performed via:
Note
"handwheel 3"
1 0 0 1
2 0 1 0
3 1 0 0
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
Corresponding to ... DB21, ... DBX37.0-2 (contour handwheel active)
Extended Functions
DB21, ...
DBX320.0-2,
DBX324.0-2,
DBX328.0-2 Activate handwheel for orientation axis (1, 2, 3)
Signal state 1 Request for activation of the corresponding handwheel for the orientation axis.
Note
"handwheel 3"
1 0 0 1
2 0 1 0
3 1 0 0
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
Corresponding to ... DB21, ... DBX332.Bit 0-2 ff. (handwheel active for orientation axis (1, 2, 3))
DB21, ...
DBX323.0,
DBX327.0,
DBX331.0 Handwheel direction of rotation inversion for orientation axis (1, 2, 3)
Signal state 1 Request for inversion of the handwheel direction of rotation assigned to orientation axis 1, 2 or 3.
Note
It is only permissible to change the inversion signal at standstill.
Signal state 0 Inversion has not been requested.
Application The handwheel direction of rotation should match the axis direction of motion.
example(s)
A handwheel is assigned to several axes with different orientations.
Corresponding to ... DB21, ... DBX335.0 ff. (handwheel direction of rotation inversion active for orientation axis 1, 2, 3)
Extended Functions
18.3.3 Signals from channel (DB21, ...)
Description of signals from channel to PLC
DB21, ...
DBX24.3 DRF selected
Signal state 1 The DRF function is active.
Signal state 0 The DRF function is not active.
Signal irrelevant for JOG mode
...
Corresponding to ... DB21, ... DBX0.3 (activate DRF)
DB21, ...
DBX33.3 Handwheel override active
Signal state 1 The function "Handwheel override in Automatic mode" is active for the programmed path axes. The
handwheel pulses of the 1st geometry axis function as a velocity override on the programmed path
feedrate.
In the following cases, the override is inactive:
The path axes have reached the programmed target position
The distance-to-go has been deleted: DB21, ... DBX6.2 == 1 (delete distance-to-go)
RESET was initiated
Signal state 0 The "Handwheel override in Automatic mode" function is not active.
DB21, ...
DBX37.0-2 Contour handwheel active
Signal state 1 Feedback signal indicating which handwheel is active for the "Contour handwheel/path input using
handwheel".
Note
"handwheel 3"
1 0 0 1
2 0 1 0
3 1 0 0
Extended Functions
DB21, ...
DBX37.0-2 Contour handwheel active
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
Signal state 0 The "Contour handwheel/path input using handwheel" is not assigned to a handwheel.
Corresponding to ... DB21, ... DBX30.0-2 (handwheel assignment for contour handwheel)
DB21, ...
DBX40.0-2,
DBX46.0-2,
DBX52.0-2 Handwheel active for geometry axis (1, 2, 3)
Signal state 1 Feedback signal indicating which handwheel is active for the geometry axis.
Note
"handwheel 3"
1 0 0 1
2 0 1 0
3 1 0 0
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
Signal state 0 None is active for the geometry axis.
Corresponding to ... DB21, ... DBX12.0-2 ff (activate handwheel)
Extended Functions
DB21, ...
DBX40.4-5,
DBX46.4-5,
DBX52.4-5 Plus or minus traversing request for geometry axis (1, 2, 3)
Signal state 1 A traversing request is available for the geometry axis for the corresponding traversing direction.
Bit 4 = minus traversing request
Bit 5 = plus traversing request
Operating modes:
JOG mode:
Plus or minus traversing key
REF mode:
Traversing key that initiates a traversing movement in the direction of the reference point.
AUTOMATIC/MDI modes:
A program block with a traversing operation is executed for a geometry axis.
Signal state 0 There is no traversing request available for the geometry axis.
Corresponding to ... DB21, ... DBX40.7 or DBX40.6
DB21, ... DBX46.7 or DBX46.6
DB21, ... DBX52.7 and/or DBX52.6 (traversing command plus and minus)
DB21, ...
DBX40.7-6,
DBX46.7-6,
DBX52.7-6 Traversing command plus and minus for geometry axis (1, 2, 3)
Description The output of the drive commands depends on:
MD17900 $MN_VDI_FUNCTION_MASK, bit 0
Bit 0 Meaning
0 The drive commands are already output when a traversing request is active.
1 The drive commands are only output when the axis traverses.
Signal state 1 Request to traverse the geometry axis in the corresponding direction.
Bit 6 = minus drive command
Bit 7 = plus drive command
The response to a drive command depends on the current operating mode:
JOG mode:
Traverse the axis in the traversing direction plus or minus.
REF mode:
Traverse the axis only in the direction of the reference point.
AUTOMATIC/MDI mode:
A block containing a position for the axis is executed.
Signal state 0 There is no traversing request available for the geometry axis.
Extended Functions
DB21, ...
DBX40.7-6,
DBX46.7-6,
DBX52.7-6 Traversing command plus and minus for geometry axis (1, 2, 3)
Application Releasing the axis clamp when the traversing command is identified.
example(s) Note
For axes on which the clamping is not released until a drive command is detected, continuous-path
mode (G64) is not possible.
Corresponding to ... DB21, ... DBX12.7 or DBX12.6 ff (traversing key plus and minus for geometry axis)
DB21, ... DBX 40, 46, 52 Bit 5 (traversing request plus/minus)
DB21, ...
DBX41.0-6,
DBX47.0-6, Active machine functions for geometry axis (1, 2, 3)
DBX53.0-6 INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous
Signal state 1 The corresponding machine function is active.
Bit 0 = 1 INC
Bit 1 = 10 INC
Bit 2 = 100 INC
Bit 3 = 1000 INC
Bit 4 = 10000 INC
Bit 5 = Var. INC
Bit 6 = continuous
The reaction to actuation of the traversing key or rotation of the handwheel varies, depending on
which machine function is active.
Signal state 0 The machine function in question is not active.
Corresponding to ... DB21, ... DBB13 bit 0-5 ff (machine function INC1, ... for geometry axis)
DB21, ... DBB13 bit 6 ff (machine function continuous for geometry axis)
DB21, ...
DBX43.0, 49.0, 55.0 Handwheel direction of rotation inversion active for geometry axis (1, 2, 3)
Signal state 1 The inversion of the handwheel direction of rotation is active for the geometry axis.
Signal state 0 The inversion of the handwheel direction of rotation is not active for the geometry axis.
Corresponding to ... DB31, ... DBX15.0, DBX19.0, DBX23.0.(invert handwheel direction of rotation for geometry axis)
Extended Functions
DB21, ...
DBX332.0-2,
DBX336.0-2,
DBX340.0-2 Handwheel active for orientation axis (1, 2, 3)
Signal state 1 Feedback signal indicating which handwheel is active for the orientation axis.
Note
"handwheel 3"
1 0 0 1
2 0 1 0
3 1 0 0
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
Signal state 0 A handwheel is not active for the orientation axis.
Corresponding to ... DB21, ... DBX332.0-2 ff (activate handwheel)
DB21, ...
DBX332.4-5,
DBX336.4-5,
DBX340.4-5 Plus and minus traversing request for orientation axis (1, 2, 3)
The signal is the same as the previous traversing command signal.
Signal state 1 JOG mode:
With the plus or minus traversing key.
REF mode:
With the traversing key that takes the axis to the reference point.
AUTOMATIC/MDI mode:
A program block containing a coordinate value for the axis in question is executed.
Extended Functions
DB21, ...
DBX332.4-5,
DBX336.4-5,
DBX340.4-5 Plus and minus traversing request for orientation axis (1, 2, 3)
Signal state 0 A traversing command in the relevant axis direction has not been given or a traversing movement
has been completed.
JOG mode:
The traversing command is reset depending on the current setting "JOG or Continuous mode"
(see DBX12.7 or DBX12.6 ff.
While traversing with the handwheel.
REF mode:
When the reference point is reached.
AUTOMATIC/MDI mode:
The program block has been executed (and the next block does not contain any coordinate
values for the axis in question).
Cancel by "RESET", etc.
interface signal DB21, DBX25.7 (axis disabled) is active.
Corresponding to ... DB31, ... DBX332.7 or DBX332.6
DB31, ... DBX336.7 or DBX336.6
DB31, ... DBX340.7 and/or DBX340.6 (traversing command plus and minus)
DB21, ...
DBX332.6-7,
DBX336.6-7,
DBX340.6-7 Traversing command plus and minus for orientation axis (1, 2, 3)
The interface signal behaves differently depending on following machine data setting:
MD17900 $MN_VDI_FUNCTION_MASK, bit 0 == 0
Behavior corresponding to the following description:
MD17900 $MN_VDI_FUNCTION_MASK, bit 0 == 1
Signal state 1: Only if the geometry axis actually traverses.
The interface signal
DB21, ... DBX 332, 336, 340 Bit 5, 4 (traversing request plus/minus)
which is always output, has the same effect as signal traversing command plus/minus with MD17900, bit 0 = 0.
Signal state 1 A traverse movement of the axis is to be executed in one or the other direction. Depending on the
mode selected, the command is triggered in different ways:
JOG mode:
With the plus or minus traversing key.
REF mode:
With the traversing key that takes the axis to the reference point.
AUTOMATIC/MDI mode:
Extended Functions
DB21, ...
DBX332.6-7,
DBX336.6-7,
DBX340.6-7 Traversing command plus and minus for orientation axis (1, 2, 3)
Signal state 0 A traversing command in the relevant axis direction has not been given or a traversing movement
has been completed.
JOG mode:
The traversing command is reset depending on the current setting "JOG or Continuous mode"
(see DB21, ... DBX12.7 or DBX12.6 ff).
REF mode:
AUTOMATIC/MDI mode:
interface signal DB21, DBX25.7 (axes disable) is active.
Application To release clamping of axes with clamping (e.g. on a rotary table).
example(s) Note:
If the clamping is not released until the traversing command is given, these axes cannot be
operated under continuous path control!
Corresponding to ... DB21, ... DBX12.7 and/or DBX12.6 ff
(traversing key plus and minus for geometry axis)
DB21, ... DBX 332, 336, 340 Bit 5, 4 (traversing request plus/minus)
DB21, ...
DBX377.4 JOG retract active
Signal state 1 JOG retract has been selected and is active.
Signal state 0 JOG retract has not been selected.
Corresponding to ... DB21, ... DBX377.5 (JOG retract: Retraction data available)
DB21, ...
DBX377.5 Retraction data available
Signal state 1 JOG retract: Retraction data is available for traversing in the tool direction. JOG retract can be
selected (user interface or PI service "RETRAC").
Signal state 0 JOG retract: Retraction data is not available for traversing in the tool direction. JOG retract cannot
be selected
Corresponding to ... DB21, ... DBX377.4 (JOG retract active)
Extended Functions
18.3.4 Signals with contour handwheel
Overview of interface signals for contour handwheel
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Description of interface signals for contour handwheel
DB10
DBX100.5 Define handwheel 1 as contour handwheel
Description These signals show which handwheel is defined as contour handwheel via the HMI:
Signal = 1 Handwheel x is defined as contour handwheel via the HMI.
Signal = 0 Handwheel x is not defined as contour handwheel.
In order for the handwheel defined via HMI to become effective as contour handwheel, the
corresponding signal has to be combined on interface signal:
DB21, ... DBX30.0, 30.1, 30.2 (activate handwheel x as contour handwheel)
.
Special cases, Depending on the settings of parameter HWheelMMC in FB1 of the basic PLC program, these
errors, ... signals are either supplied by the basic program or must be supplied by the PLC user program.
Corresponding to ... DB21 ... DBX30.0, 30.1, 30.2 (activate handwheel x as contour handwheel)
FB1 parameters HWheelMMC
DB21, ...
DBX30.0 Activate handwheel 1 as contour handwheel;
DBX30.2 Activate handwheel 3 as contour handwheel
Description One of the three handwheels can be selected/deselected as contour handwheel via these signals:
Signal = 1 Handwheel x is selected as contour handwheel
Signal = 0 Handwheel x is deselected as contour handwheel
Extended Functions
DB21, ...
DBX30.2 Activate handwheel 3 as contour handwheel
Enabling/disabling of the contour handwheel can be performed in the middle of a block.
Upon enabling, the movement is first decelerated and then traversed according to the contour
handwheel.
Upon disabling, the movement is decelerated and the NC program is continued immediately. If the
NC program is to be continued only after a new NC Start, then deactivation of the contour
handwheel in the PLC user program must be combined with an NC Stop.
Special cases, The signal is kept beyond an NC Reset.
errors, ...
Corresponding to ... DB21, ... DBX37.0, 37.1, 37.2 (handwheel x active as contour handwheel)
DB21, ...
DBX30.3 Simulation contour handwheel on
DBX30.4 Negative direction simulation contour handwheel
Description For enabling/disabling simulation of the contour handwheel, and for definition of the traversing
direction, these signals have to be set as follows:
Bit 3 Bit 4 Meaning
0 0 Simulation off
0 1 Simulation off
1 0 Simulation On, direction as programmed
1 1 Simulation On, direction opposite programmed direction
During simulation, the feedrate is no longer defined by the contour handwheel, but traversing
occurs with the programmed feedrate on the contour.
When the function is deselected, the current movement is decelerated by the braking ramp.
When the traversing direction is switched, the current movement is decelerated by the braking
ramp, and traversing occurs in the opposite direction.
Special cases, Simulation is only effective in AUTOMATIC mode and can only be activated when the contour
errors, ... handwheel is activated.
DB21, ...
DBX31.5 Invert handwheel direction of rotation for contour handwheel
Description You can invert the direction of rotation of a contour handwheel by setting this PLC interface signal.
Application The direction of movement of the handwheel does not match the expected direction of the axis.
example(s)
A handwheel (HT2, HT8) has been assigned to various axes.
Special cases, It is only permissible to change the inversion signal at standstill.
errors, ...
Corresponding to ... DB31, ... DBX39.5 (handwheel direction of rotation inversion active for contour handwheel)
Extended Functions
DB21, ...
DBX37.0 Handwheel 1 active as contour handwheel
Description These signals show which handwheel is selected as contour handwheel:
Signal = 1 Handwheel x is selected as contour handwheel.
Signal = 0 Handwheel x is deselected as contour handwheel.
Special cases, The signal is kept beyond an NC Reset.
errors, ...
Corresponding to ... DB21, ... DBX30.0, 30.1, 30.2 (handwheel x active as contour handwheel)
DB21, ...
DBX39.5 Handwheel direction of rotation inversion active for contour handwheel
Description This signal indicates whether the direction of rotation was inverted for the contour handwheel:
Signal = 1 The direction of rotation of the contour handwheel is inverted.
Signal = 0 The direction of rotation of the contour handwheel is not inverted.
Corresponding to ... DB31, ... DBX31.5 (invert handwheel direction of rotation for the contour handwheel)
18.3.5 Signals to axis/spindle (DB31, ...)
Description of signals to axis/spindle
DB31, ...
DBB4
Bit 0-2 Activate handwheel (1 to 3)
Signal state 1 or This PLC interface signal defines whether this machine axis is assigned to handwheel 1, 2, 3 or no
edge change 0 1 handwheel.
Only one handwheel can be assigned to an axis at any one time.
If several interface signals:
DB31, ... DBX4.0, 4.1, 4.2 (Activate handwheel)
are set, priority "Handwheel 1" before "Handwheel 2" before "Handwheel 3" applies.
If the assignment is active, the machine axis can be traversed with the handwheel in JOG mode or
a DRF offset can be generated in AUTOMATIC or MDA mode.
Signal state 0 or Neither handwheel 1, 2 nor 3 is assigned to this geometry axis.
edge change 1 0
Application The PLC user program can use this interface signal to disable the influence of turning the
example(s) handwheel on the axis.
Corresponding to ... DB31, ... DBX64.0 to DBX64.2 (Handwheel active)
Extended Functions
DB31, ...
DBX4.4 Traversing key lock
Signal state 1 or The traverse keys plus and minus have no effect on the machine axes in question. It is thus not
edge change 0 1 possible to traverse the machine axis in JOG with the traverse keys on the machine control panel.
If the traverse key disable is activated during a traverse movement, the machine axis is stopped.
Signal state 0 or The plus and minus traverse keys are enabled.
edge change 1 0
Application It is thus possible, depending on the operating mode, to disable manual traverse of the machine
example(s) axis in JOG mode with the traverse keys from the PLC user program.
Corresponding to ... DB31, ... DBX4.7 and/or DBX4.6 (traversing key plus and traversing key minus)
DB31, ...
DBX4.5 Rapid traverse override
Signal state 1 or If together with interface signal:
edge change 0 1 DB31, ... DBX4.0, 4.1, 4.2 (traverse key plus or traverse key minus)
the PLC interface signal:
DB31, ... DBX4.5 (Rapid traverse override)
is sent, then the corresponding machine axis is operating with rapid traverse.
The rapid traverse feedrate is defined in machine data:
MD32010 $MA_JOG_VELO_RAPID (Conventional rapid traverse)
.
The rapid traverse override is effective in the JOG mode for the following versions:
Continuous jogging
Incremental jogging
If rapid traverse override is active, the velocity can be modified with the rapid traverse override
switch.
Signal state 0 or The machine axis traverses with the defined JOG velocity:
edge change 1 0 SD41110 $SN_JOG_SET_VELO (Axis velocity with JOG)
or
MD32020 $MA_JOG_VELO (Conventional axis velocity).
Signal irrelevant for Operating modes AUTOMATIC and MDA
... Reference point approach (JOG mode)
DB31, ... DBB0 (axial feed/spindle override)
Extended Functions
DB31, ...
DBB4
Bit 7, 6 Plus and minus traverse keys
Signal state 1 The selected machine axis can be traversed in both directions in JOG mode using the traversing
keys "plus" and "minus".
Depending on the active machine function, as well as the settings:
JOG (continuous)
SD41050 $SN_JOG_CONT_MODE_LEVELTRIGGRD (jog/ continuous operation for JOG
continuous)
JOG-INC (INC and REF in the jog mode)
MD11300 $MN_JOG_INC_MODE_LEVELTRIGGRD
for a signal change, different responses are initiated.
Case 1: Continuous traversal in jog mode
The machine axis traverses in the direction concerned as long as the interface signal
is set to 1 (and as long as the axis position has not reached an activated limitation).
Case 2:Continuous traversal in continuous mode
On the first edge change 0 1 the machine axis starts to traverse in the relevant direction. This
traversing movement still continues when the edge changes from 1 0. Any new edge change
0 1 (same traversing direction!) stops the traversing movement.
Case 3:Incremental traversal in jog mode
With signal 1 the machine axis starts to traverse at the set increment. If the signal changes to the 0
state before the increment is traversed, the traversing movement is interrupted. When the signal
state changes to 1 again, the movement is continued. The axis can be stopped and started several
times as described above until it has traversed the complete increment.
Case 4: Incremental traversal in continuous mode
On the first edge change 0 1 the machine axis starts to traverse at the set increment. If another
edge change 0 1 is performed with the same traverse signal before the axis has traversed the
increment, the traversing movement will be cancelled. The increment traversing will then not be
completed.
If both traverse signals (plus and minus) are set at the same time there is no movement or a
current movement is aborted.
The effect of the traverse keys can be disabled for every machine axis individually with the PLC
interface signal:
DB31, ... DBX4.4 (Traverse key disable)
.
Signal state 0 See cases 1 to 4 above.
Signal irrelevant for Operating modes AUTOMATIC and MDA
...
Application The machine axis cannot be traversed in JOG mode if it is already being traversed via the channel-
example(s) specific PLC interface (as a geometry axis).
Alarm 20062 is signaled.
Special cases, ... Indexing axes
Corresponding to ... DB21, ... DBX12.7, DBX12.6 ff (Traverse keys plus and minus for geometry axes)
DB31, ... DBX4.4 (traversing key disable)
Extended Functions
DB31, ...
DBB5
Bit 0-5 Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar
Signal state 1 Request to activate a machine function for incremental traversing of the axis:
Bit 0: INC1
Bit 1: INC10
Bit 2: INC100
Bit 3: INC1000
Bit 4: INC10000
Bit 5: INCvar
One increment corresponds to actuating the traversing key or a detent position of the handwheel.
The size of an increment is defined in the following system data:
INC1 to INC10000:
MD11330 $MN_JOG_INCR_SIZE_TAB (increment size for INC/handwheel)
INCvar:
The feedback signal indicating that the machine function has been activated is realized via:
DB31, ... DBB65 (machine function INC1, ...)
Notice
If several bits are simultaneously set, then no machine function is active in the control.
Signal state 0 The corresponding machine function is not requested.
If the axis is presently traversing an increment, motion is canceled when the machine function is
either selected or changed over.
Corresponding to ... DB31, ... DBB65 (machine function INC1, ...)
DB31, ... DBX5.6 (Machine function continuous)
DB31, ...
DBX5.6 Continuous machine function
Signal state 1 The machine axis can be continuously traversed with the traversing keys "plus" and "minus" in the
JOG mode.
Signal state 0 The machine function "Continuous jogging" is not selected.
Corresponding to ... DB31, ... DBB65 (active machine function INC1, ..., continuous)
DB31, ... DBB5 (machine function INC1, ..., INC10000)
DB31, ...
DBX7.0 Invert handwheel direction of rotation (machine axes)
Signal state 1 The direction of rotation of the handwheel, which is assigned to the machine axes, is inverted.
It is only permissible to change the inversion signal at standstill.
Extended Functions
DB31, ...
DBX7.0 Invert handwheel direction of rotation (machine axes)
Signal state 0 The handwheel direction of rotation is not inverted.
Application The direction of movement of the handwheel does not match the expected direction of the axis.
example(s)
The handwheel is assigned to different axes with different orientations.
Corresponding to ... DB31, ... DBX67.0 (handwheel direction of rotation inversion active for machine axes)
DB31, ...
DBB13
Bit 0-2 JOG - approach fixed point
Signal state 1 Activates the "approaching fixed point JOG" function.
The number of the fixed point to be approached is specified in bits 0-2 in binary code.
The selected machine axis can be traversed to the corresponding fixed point with the traverse keys
or the handwheel as soon as the function is active (see DB31, ... DBX75.0-2).
The fixed points are defined using the following machine data:
MD30600 $MA_FIX_POINT_POS[n]
Signal state 0 Deactivates the "approaching fixed point JOG" function.
Corresponding to ... DB31, ... DBX75.0-2 (JOG - Approach fixed point)
DB31, ... DBX75.3-5 (JOG - Approach fixed point)
MD30600 $MA_FIX_POINT_POS[n] (fixed value positions of the axis)
Extended Functions
Description of signals from axis/spindle
DB31, ...
DBX62.1 Handwheel override active
Signal state 1 or The function "Handwheel override in AUTOMATIC mode" is active for the programmed positioning
edge change 0 1 axis (FDA[AXi]). Handwheel pulses for this axis affect the programmed axis feedrate either as path
definition (FDA=0) or as velocity override (FDA > 0).
The interface signal will also be set if "Handwheel override in automatic mode" is active with a
concurrent positioning axis with FC18 ( for 840D sl).
Signal state 0 or The function "Handwheel override in AUTOMATIC mode" is not active for the programmed
edge change 1 0 positioning axis (or concurrent positioning axis).
An active handwheel override is not active if:
the positioning axis has reached the target position
the distance-to-go is deleted by axis-specific interface signal
DB31, ... DBX2.2 (delete distance-to-go).
a RESET is performed.
DB31, ...
DBB64
Bit 0-2 Handwheel active (1 to 3)
Signal state 1 or These PLC interface signals provide feedback whether the machine axis is assigned to handwheel
edge change 0 1 1, 2, 3 or no handwheel.
Only one handwheel can be assigned to an axis at any one time.
If several interface signals:
DB31, ... DBX4.0 to DBX4.2 (Activate handwheel)
are set, priority "Handwheel 1" before "Handwheel 2" before "Handwheel 3" applies.
If the assignment is active, the machine axis can be traversed with the handwheel in JOG mode or
a DRF offset can be generated in AUTOMATIC or MDA mode.
Signal state 0 or Neither handwheel 1, 2 nor 3 is assigned to this geometry axis.
edge change 1 0
Corresponding to ... DB31, ... DBX4.0 to DBX4.2 (activate handwheel)
DB10 DBB100.6 ff (handwheel selected)
Extended Functions
DB31, ...
DBB64
Bit 5, 4 Plus and minus traversing request
Signal state 1 or A traverse movement of the axis is to be executed in one or the other direction. Depending on the
edge change 0 1 mode selected, the command is triggered in different ways:
JOG mode:
With the plus or minus traverse key.
REF mode:
With the traverse key that takes the axis to the reference point.
AUT/MDA mode:
Signal state 0 or A traversing command in the relevant axis direction has not been given or a traverse movement
edge change 1 0 has been completed.
JOG mode:
The traversing command is reset depending on the current setting "jog or continuous mode"
(see interface signal DB31, ... DBX4.7 or DBX4.6).
REF mode:
AUT/MDA mode:
DB21, DBX25.7 (axes disable) is active.
example(s) Note:
DB31, ... DBX64.7 and/or DBX64.6 (Traversing command plus and minus)
DB31, ...
DBB64
Bit 7, 6 Plus and minus traversing command
The signal has the effect as described, if Bit 0 in the machine data:
MD17900 $MN_VDI_FUNCTION_MASK (setting for VDI signals)
is set to 0.
If bit 0 in the MD is set to 1, then the signal changes to 1 only if the axis is actually moving.
The interface signal
DB31, ... DBX64 Bit 5, 4 (traversing request plus/minus)
, which is always output, has the same effect as signal traversing command plus/minus when MD17900 bit 0 = 0.
Extended Functions
DB31, ...
DBB64
Bit 7, 6 Plus and minus traversing command
Signal state 1 or A traverse movement of the axis is to be executed in one or the other direction.
edge change 0 1 Depending on the mode selected, the command is triggered in different ways:
JOG mode:
With the plus or minus traverse key.
REF mode:
With the traverse key that takes the axis to the reference point.
AUT/MDA mode:
Signal state 0 or A traversing command in the relevant axis direction has not been given or a traverse movement
edge change 1 0 has been completed.
JOG mode:
The traversing command is reset depending on the current setting "jog or continuous mode"
(DB31, ... DBX4.7 and/or DBX4.6).
REF mode:
AUT/MDA mode:
DB21, DBX25.7 (axes disable) is active.
example(s) Note:
DB31, ... DBX64.5 and/or DBX.4 (Traversing request plus and minus)
DB31, ...
DBB65
Bit 0-6 Active machine function INC1, ..., continuous
Signal state 1 or The PLC interface receives a signal stating which JOG mode machine function is active for the
edge change 0 1 machine axes.
The reaction to actuation of the traverse key or rotation of the handwheel varies, depending on
which machine function is active.
Signal state 0 or The machine function in question is not active.
edge change 1 0
Corresponding to ... DB31, ... DBB5 (machine function INC1, ..., continuous)
Extended Functions
18.4 Compensations (K3)
DB31, ...
DBX67.0 Invert handwheel direction of rotation active (machine axes)
Description For a handwheel, which is assigned to a machine axis, this signal indicates whether the direction of
rotation was inverted:
Signal = 1 The direction of rotation of the handwheel is inverted.
Signal = 0 The direction of rotation of the handwheel is not inverted.
Corresponding to ... DB31, ... DBX7.0 (invert handwheel direction of rotation for machine axes)
DB31, ...
DBB75
Bit 0-2 JOG - Approaching fixed point active
Signal state 1 or Message to the PLC that the function "Approaching fixed point in JOG" is effective.
edge change 0 1 The selected machine axis can be traversed to the specified fixed point binary-coded via Bit 0-2
with the traverse keys or the handwheel.
Signal state 0 or "Approaching fixed point in JOG" is not active
edge change 1 0
DB31, ...
DBB75
Bit 3-5 JOG - Approaching fixed point reached
Signal state 1 or Message to PLC that the selected axis has reached the approaching fixed point with "exact stop
edge change 0 1 fine" by virtue of the traversing motion in JOG.
This display signal is also signaled if the axis reaches the fixed point position in the machine
coordinates system via other methods e.g. NC program, FC18 (for 840D sl) or synchronized action
on the setpoint side and comes to a standstill on the actual value side within the "Exact stop fine"
tolerance window (MD36010 $MA_STOP_LIMIT_FINE).
Signal state 0 or The axis has not yet reached the approaching fixed point.
edge change 1 0
18.4 Compensations (K3)

No signal descriptions required.
Extended Functions
18.5 Mode Groups, Channels, Axis Replacement (K5)
18.5 Mode Groups, Channels, Axis Replacement (K5)
DB31, ...
DBB8 Axis/spindle replacement
Edge evaluation: Yes Signal(s) updated: Cyclic
Signal state 1 or The current axis type and currently active channel for this axis must be specified.
edge change 0 1 With axis replacement by the PLC, the bit meanings of the signal to axis/spindle DB31, ... DBB8:
Bit 0: Assign A NC axis/spindle channel
Bit 1: B ...
Bit 2: C ....
Bit 3: Assign D NC axis/spindle channel
Bit 4: Activation, assignment by means of a positive edge
Bit 5: -
Bit 6: -
Bit 7: Request PLC axis/spindle
Signal state 0 or
edge change 1 0
Corresponding to .... DB31, ... DBB68 (Axis/spindle replacement)
MD20070 $MC_AXCONF_ASSIGN_MASTER_USED
(Machine axis number valid in channel)
(Initial setting of channel for axis replacement)
Special cases, errors,
...
Extended Functions
18.6 Kinematic Transformation (M1)
DB31, ...
DBB68 Axis/spindle replacement
Signal state 1 or The current axis type and currently active channel for this axis is displayed.
edge change 0 1 With axis replacement by the PLC, the bit meanings of the signal from axis/spindle DB31, ...
DBB68:
Bit 0: A NC axis/spindle in channel
Bit 1: B ...
Bit 2: C ....
Bit 3: D NC axis/spindle in channel
Bit 4: New type requested from PLC
Bit 5: Axis replacement possible
Bit 6: neutral axis/spindle as well as command/oscillation axes
Bit 7: PLC axis/spindle
Signal state 0 or
edge change 1 0
Corresponding to .... DB31, ... DBB8 (Axis/spindle replacement)
MD20070 $MC_AXCONF_ASSIGN_MASTER_USED
(Machine axis number valid in channel)
(Initial setting of channel for axis replacement)
Special cases, errors,
...
18.6 Kinematic Transformation (M1)
DB21, ...
DBX33.6 Transformation active
Signal state 1 or The NC command TRANSMIT, TRACYL, TRAANG or TRAORI is programmed in the part program. The
edge change 0 1 corresponding block has been processed by the NC and a transformation is now active.
Signal state 0 or No transformation active.
edge change 1 0
References Programming Guide Advanced
Function Description, Special Functions; 3-Axis to 5-Axis Transformation (F2)
Extended Functions
18.7 Measurement (M5)
18.7 Measurement (M5)
DB10
DBX107.0 and
DBX107.1 Probe actuated
Signal state 1 or Probe 1 or 2 is actuated.
edge change 0 1
Signal state 0 or Probe 1 or 2 is not actuated.
edge change 1 0
References Equipment Manual NCU
DB31, ...
DBX62.3 Measuring status
Signal state 1 or The "Measuring" function is active.
edge change 0 1 This signal is used during measuring and displays the current measuring status of the axis.
Signal state 0 or The "Measuring" function is not active.
edge change 1 0
Extended Functions
18.8 Software cams, position switching signals (N3)
18.8.1 Signal overview
PLC interface signals for "Software cams, position switching signals"
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Extended Functions
DB10
DBX110.0-113.7 Minus cam signal 1-32
Signal state 1 or The switching edge of the minus cam signal 1-32 is generated as a function of the traversing
edge change 0 1 direction of the (rotary) axis and transferred to the PLC interface in the IPO cycle.
Linear axis:
The minus cam signal switches from 0 to 1 if the axis overtravels the minus cam in the negative
axis direction.
Modulo rotary axis:
The minus cam signal changes level in response to every positive edge of the plus cam signal.
Signal state 0 or Linear axis:
edge change 1 0 The minus cam signal switches from 1 to 0 when the axis traverses the minus cam in the positive
axis direction.
Modulo rotary axis:
The minus cam signal changes level in response to every positive edge of the plus cam signal.
DB10
DBX114.0-117.7 Plus cam signal 1-32
Signal state 1 or The switching edge of the plus cam signal 1-32 is generated as a function of the traversing
edge change 0 1 direction of the (rotary) axis and transferred to the PLC interface in the IPO cycle.
Linear axis:
The plus cam signal switches from 0 to 1 when the axis traverses the plus cam in the positive
direction.
Modulo rotary axis:
The plus cam signal switches from 0 to 1 when the minus cam is overtraveled in the positive axis
direction.
The described response of the plus cam applies under the condition:
If this condition is not fulfilled or if the minus cam is set to a greater value than the plus cam, then
the response of the plus cam signal is inverted. The response of the minus cam signal remains
unchanged.
Signal state 0 or Linear axis:
edge change 1 0 The plus cam signal switches from 1 to 0 if the axis overtravels the plus cam in the negative
direction.
Modulo rotary axis:
The plus cam signal switches from 1 back to 0 if the plus cam is overtraveled in the positive axis
direction.
The described response of the plus cam applies under the condition:
If this condition is not fulfilled or if the minus cam is set to a greater value than the plus cam, then
the response of the plus cam signal is inverted. The response of the minus cam signal remains
unchanged.
Extended Functions
DB31, ...
DBX2.0 Cam activation
Signal state 1 or Output of the minus and plus cam signals of an axis to the general PLC interface is activated.
edge change 0 1 The activation takes effect immediately after processing of IS "Cam activation".
Signal state 0 or The minus and plus cam signals of an axis are not output to the general PLC interface.
edge change 1 0
Corresponding to .... DB10 DBX110.0 - 113.7 (minus cam signal 1-32)
DB10 DBX114.0 - 117.7 (plus cam signals 1-32)
DB31, ...
DBX62.0 Cams active
Signal state 1 or All cams of the axis selected via NC/PLC interface signal:
edge change 0 1 DB31, ... DBX2.0 (Cam activation)
have been activated successfully.
Signal state 0 or The cams of the axis are not activated.
edge change 1 0
Corresponding to .... DB31, ... DBX2.0 (Cam activation)
DB10 DBX110.0 - 113.7 (minus cam signal 1-32)
DB10 DBX114.0 - 117.7 (plus cam signals 1-32)
Extended Functions
18.9 Punching and Nibbling (N4)
18.9.1 Signal overview
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Figure 18-1 PLC interface signals for "Punching and nibbling"
18.9.2 Signals to channel (DB21, ...)
DB21, ...
DBX3.0 No stroke enable
Signal state 1 or This signal releases the punching strokes via the PLC.
edge change 0 1 1 signal: The stroke is locked, the NC may not trigger a punching stroke.
Signal state 0 or 0 signal: Punching stroke is available. As long as release is not set, the NC may perform a
edge change 1 0 punching stroke
DB21, ...
DBX3.1 Manual stroke initiation
Signal state 1 or This signal enables the triggering of a single stroke in manual mode.
edge change 0 1 1 signal: Manual stroke is performed.
Signal state 0 or 0 signal: No effect.
edge change 1 0
Extended Functions
DB21, ...
DBX3.2 Stroke suppression
Signal state 1 or This signal simply prevents execution of the stroke. The machine traverses anyway.
edge change 0 1 The automatic path segmentation remains active if it is already activated.
Only the signal "Stroke initiation" is suppressed.
The machine traverses in "stop and go" mode.
The step length is defined via the path segmentation.
1 signal: Stroke suppression is active.
Signal state 0 or 0 signal: Stroke suppression is not active.
edge change 1 0
DB21, ...
DBX3.3 Delayed stroke
Signal state 1 or A "Delayed stroke" can be activated via this signal. This corresponds in function to the
edge change 0 1 programming of PDELAYON. Other PLC signals not corresponding to the standard are not evaluated
in the NCK. With the exception of the manual stroke initiation, the evaluation of signals is limited to
PON active.
1 signal: Delayed stroke is active.
Signal state 0 or 0 signal: Delayed stroke is not active.
edge change 1 0
DB21, ...
DBX3.4 Stroke inoperative
Signal state 1 or The NC reacts to this signal by initiating an immediate movement stop. An alarm is output if any
edge change 0 1 other movement or action needs to be interrupted as a result of this signal.
In physical terms, the signal is identical to the signal "Stroke active" for the CNC, i.e. the system is
wired in such a way that the two signals are taken to the same NC input via an AND gate.
1 signal: Stroke inoperative (corresponds to the signal "stroke enable").
Signal state 0 or 0 signal: Stroke operative (corresponds to the signal "stroke enable").
edge change 1 0
Extended Functions
DB21, ...
DBX3.5 Manual stroke initiation
Signal state 1 or The signal "manual stroke initiation" allows the operator to initiate a punching process, even when
edge change 0 1 the parts program is not being processed. Thus the initiation of the punching process is controlled
from the PLC.
Successful stroke initiation is indicated to the PLC by the NCK-PLC interface signal:
DB21, ... DBX38.1 (Manual stroke initiation acknowledgement)
.
1 signal: Manual stroke initiation is active.
Signal state 0 or 0 signal: Manual stroke initiation is not active.
edge change 1 0
DB21, ...
DBX38.0 Stroke initiation active
Signal state 1 or This signal displays whether the stroke initiation is active.
edge change 0 1 1 signal: Stroke initiation is active.
Signal state 0 or 0 signal: Stroke initiation is not active.
edge change 1 0
DB21, ...
DBX38.1 Acknowledgement of manual stroke initiation
Signal state 1 or This signal displays whether a manual stroke has been initiated.
edge change 0 1 1 signal: Manual stroke has been performed.
Signal state 0 or 0 signal: Manual stroke has not been performed.
edge change 1 0
Extended Functions
18.10 Positioning axes (P2)

The following signals or commands on the NCK-HMI-PLC interface are only of significance
for the positioning axis:
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Figure 18-2 Signal modification by the PLC
DB31, ...
DBB0 Feedrate override / spindle override axis-specific
Signal state 1 or edge Positioning axes have their own axis-specific feedrate override value. This feedrate override
change 0 1 is evaluated in the same way as the channel-specific feedrate override.
Signal irrelevant for ... NST DB31, ... DBX74.5 ("Positioning axis") = ZERO
References Evaluation see:
DB21, ... DBB4 (feedrate override); channel-specific
DB31, ...
DBX2.2 Delete distance-to-go, axis-specific
Signal state 1 or edge The axis-specific distance-to-go of the positioning axis is canceled. The positioning axis is
change 0 1 decelerated and the following error is eliminated. The programmed end position is deemed to
have been reached. The path axes are not influenced by the axis-specific "delete distance-to-
go" interface signal. The channel-specific "delete distance-to-go" interface signal is used for
this purpose.
Special cases, If the axis-specific "delete distance-to-go" interface signal is enabled, even if no positioning
errors, ... axes have been programmed in this block, the NCK does not respond.
Corresponding to ... DB21, ... DBX6.2 (delete distance-to-go); channel-specific for path axes
Extended Functions
DB31, ...
DBX28.1 Reset
Signal state 1 or edge Reset request to the NCK for the PLC-controlled axis/spindle.
change 0 1 Feedback signal from the NCK to the PLC:
DB31 ... DBX63.1 = 1 (reset executed)
DB31 ... DBX63.2 = 1 (axis stop active)
Special cases, Boundary condition:
errors, ...
The axis/spindle must be currently controlled by the PLC.
Corresponding to ... DB31 ... DBX63.1 (reset executed)
DB31, ... DBX63.2 (axis stop active)
System variable: $AA_SNGLAX_STAT
OPI variables: aaSnglAxStat
DB31, ...
DBX28.2 Continue
Signal state 1 or edge Request to continue interrupted traversing motion for a PLC-controlled axis/spindle.
change 0 1 The request can be interrupted with DB31 DBX63.2 ("axis stop active").
Special cases, Boundary condition:
errors, ...
The axis/spindle must be currently controlled by the PLC.
The signal is ignored for following error situations:
The axis/spindle is not controlled by the PLC.
The axis/spindle is not in the stopped state.
The axis/spindle must not resume traversing because an alarm is present.
Corresponding to ... DB31, DBX28.1 (reset)
DB31, ... DBX60.6 (exact stop coarse)
DB31, ... DBX60.7 (exact stop fine)
DB31 ... DBX63.2 (axis stop active)
DB31, ... DBX64.6 (traversing command minus)
OPI variables: aaSnglAxStat
Extended Functions
DB31, ...
DBX61.1 Axial alarm
Signal state 1 or edge Effects:
change 0 1
The axis/spindle is stopped by the NCK via a braking ramp.
OPI variables: aaSnglAxStat = 5 (alarm)
$AA_SNGLAX_STAT = 5 (axial alarm is present)
DB31 ... DBX61.1 = 1 (axial alarm)
DB31, ...
DBX63.0 Reset executed
Signal state 1 or edge The following state is present after the reset:
change 0 1
The machine data of the axis/spindle is reloaded
DB31 ... DBX63.0 == 1 (reset executed)
DB31 ... DBX63.2 == 0 (axis stop active)
System variable $AA_SNGLAX_STAT == 1
OPI variables: aaSnglAxStat == 1
Corresponding to ... DB31, DBX28.1 (reset)
DB31, ...
DBX63.1 PLC-controlled axis
Signal state 1 or edge Confirmation of the NC to the PLC that the axis is now controlled by the PLC.
change 0 1
Corresponding to ... DB31 ... DBX28.7 (PLC controls the axis)
DB31,
DBX63.2 Axis stop active
Signal state 1 or edge Signal from the NC to the PLC that the axis will be stopped.
change 0 1
Extended Functions
DB31,
DBX63.2 Axis stop active
Signal state 0 or edge Confirmation from the NC to the PLC that the axis has been stopped.
change 1 0 System variable: $AA_SNGLAX_STAT = 3 (single axis is interrupted)
Corresponding to ... DB31, ... DBX60.6 (exact stop coarse)
DB31, ... DBX60.7 (exact stop fine)
DB31 ... DBX63.2 (axis stop active)
DB31, ... DBX64.6 (traversing command minus)
DB31, ...
DBX76.5 Positioning axis
Signal state 1 or edge Confirmation from the NC to the PLC that the axis is a positioning axis.
change 0 1
DB31, ...
DBD78 F function (feedrate) for positioning axis
Edge evaluation: No Signal(s) updated: when change
Function The axial feedrate programmed for the positioning axis.
The value specified by FC18 for 840D sl is not output.
Signal irrelevant for ... DB31, ... DBX76.5 == 0 (axis is not a positioning axis)
Special cases, If the positioning axis is traversed with the feedrate from the machine data, the NC does not
errors, ... output an F function (feed) to the PLC:
Corresponding to ... DB31, ... DBX76.5 (positioning axis)
MD22240 $MC_AUXFU_F_SYNC_TYPE (output time of F functions)
Extended Functions
18.11 Oscillation (P5)
18.10.2 Function call - only 840D sl
FC18
For SINUMERIK 840D sl, concurrent positioning axes can be started from the PLC using
FC18 (Function Call 18) of the PLC. The following parameters are passed to the function
call:
Axis name/axis number
End position
Feedrate
(for feedrate = 0, the feedrate is taken from MD32060 $MA_POS_AX_VELO)
The F value of FC18 is nottransferred to the axis-specific IS DB31, ...DBB78-81 ("F
function (feedrate) for positioning axis")
Absolute coordinates (G90), incremental coordinates (G91), absolute coordinates along
the shortest path for rotary axes (rotary axis name = DC(value))
Since each axis is assigned to exactly one channel, the control can select the correct
channel from the axis name/axis number and start the concurrent positioning axis on this
channel.
Reference:
Function Manual Basic Functions; PLC Basic Program for SINUMERIK 840D sl (P3)
VDI input signals

The PLC user program uses the following signals to control the oscillation process.
DB31, ...
DBX28.0 External oscillation reversal
Signal state 1 or edge Brake oscillation motion and move oscillation axis in the opposite direction.
change 0 1
Signal state 0 or edge Continue oscillation without interruption
change 1 0
Extended Functions
DB31, ...
DBX28.3 Set reversal point
Signal state 1 or edge Reversal point 2
change 0 1
Signal state 0 or edge Reversal point 1
change 1 0
DB31,
DBX28.4 Alter reversal point
Signal state 1 or edge The selected reversal point can be altered by manual traverse.
change 0 1 In conjunction with DB31, ...DBX28.0:
The position at which axis is braked after external oscillation reversal must be accepted as
new reversal point.
Signal state 0 or edge The selected reversal point cannot be altered by manual traverse.
change 1 0 In conjunction with DB31, ...DBX28.0:
No change to reversal point
Corresponding to .... DBX28.3
DB31, ...
DBX28.5 Stop at next reversal point
Signal state 1 or edge The oscillation movement is interrupted at the next reversal point.
change 0 1
Signal state 0 or edge The oscillation movement continues after the next reversal point.
change 1 0
Corresponding to .... DBX28.6, DBX28.7
DB31, ...
DBX28.6 Stop along braking ramp
Signal state 1 or edge The axis is decelerated along a ramp, the oscillation movement is interrupted.
change 0 1
Signal state 0 or edge The oscillation movement continues without interruption.
change 1 0
Extended Functions
DB31, ...
DBX28.7 PLC controls axis
Signal state 1 or Axis is controlled by the PLC.
edge change The reaction to interface signals is controlled by the PLC by means of the 2 stop bits, other
01 signals with deceleration action are ignored.
Signal state 0 or Axis is not controlled by the PLC.
edge change
10
VDI output signals

The NCK makes the following signals available to the PLC user program.
DB31, ...
DBX100.2 Oscillation reversal active
Signal state 1 or edge The deceleration period after external oscillation reversal (DB31, ...DBX28.0) is active
change 0 1
Signal state 0 or edge No deceleration after external oscillation reversal is active
change 1 0
DB31, ...
DBX100.3 Oscillation cannot start
Signal state 1 or edge The oscillation axis cannot be started owing to incorrect programming. This status can occur
change 0 1 even when axis has already been traversed.
Signal state 0 or edge The oscillation movement can be started.
change 1 0
DB31, ...
DBX100.4 Error during oscillation movement
Signal state 1 or edge The oscillation movement has been aborted.
change 0 1
Signal state 0 or edge The oscillation movement is being executed correctly.
change 1 0
Extended Functions
DB31,
DBX100.5 Sparking-out active
Signal state 1 or edge The axis is executing sparking-out strokes.
change 0 1
Signal state 0 or edge The axis is not currently executing sparking-out strokes.
change 1 0
DB31, ...
DBX100.6 Oscillation movement active
Signal state 1 or edge The axis is executing an oscillation movement between 2 reversal points.
change 0 1
Signal state 0 or edge The axis is not currently oscillating.
change 1 0
Signal irrelevant DBX100.7 = 0
for ......
DB31, ...
DBX100.7 Oscillation active
Signal state 1 or edge The axis is currently being traversed as an oscillation axis.
change 0 1
Signal state 0 or edge The axis is a positioning axis.
change 1 0
DB31, ...
DBX104.0 - 7 Active infeed axes
Signal state 1 or edge The axis sending the signal is currently the oscillation axis and is indicating its active infeed
change 0 1 axes in this field (104.0 axis 1 is infeed axis, 104.1 axis 2 is infeed axis, etc.).
Signal state 0 or edge The associated axis is not an infeed axis.
change 1 0
Extended Functions
18.12 Rotary axes (R2)
18.12 Rotary axes (R2)
DB31, ...
DBX12.4 Traversing range limitation for modulo rotary axes
Signal state 1 or Activate traversing range limitation for modulo rotary axes
edge change 0 1 (software end switches, work field limitations).
Signal state 0 or Deactivate traversing range limitation for modulo rotary axes.
edge change 1 0
Signal irrelevant for Linear axes / rotary axes without modulo functionality.
...
Application Built-on rotary axis with monitoring
example(s)
DB31, ...
DBX74.4 Monitoring status with modulo rotary axes
Signal state 1 or Traversing range limitation for modulo rotary axes active
edge change 0 1 (software end switches, work field limitations).
Signal state 0 or Traversing range limitation for modulo rotary axes not active.
edge change 1 0
Signal irrelevant for Linear axes / rotary axes without modulo functionality.
...
Application Built-on rotary axis with monitoring
example(s)
Extended Functions
18.13 Synchronous Spindles (S3)
DB31, ...
DBX31.5 Disable synchronization
Signal state 1 or edge The synchronization motion for the following spindle is not disabled from the PLC.
change 0 1 The position offset is not suppressed and applied as in earlier versions.
Signal state 0 or edge The synchronization motion for the following spindle is disabled from the PLC.
change 1 0 A synchronization motion specified via offset programming is suppressed for the following
spindle. The following spindle does not execute any additional movement.
Corresponding to .... DB31, ... DBX98.1 (Synchronism coarse)
DB31, ... DBX98.0 (Synchronism fine)
DB31, ...
DBX84.4 Synchronous mode
Signal state 1 or edge The spindle is operating in "Synchronous operation" mode. The following spindle thus follows
change 0 1 the movements of the leading spindle in accordance with the transmission ratio.
The monitoring functions for coarse and fine synchronism are implemented in synchronous
operation.
Note:
The signal is set only for the machine axis which is acting as following spindle
(IS "FS active" = 1)
Signal state 0 or edge The spindle is not operated as the following spindle in "synchronous mode".
change 1 0 When the coupling is deactivated (deselection of synchronous operation), the following
spindle is switched to "open-loop control mode".
Corresponding to .... DB31, ... DBX98.0 (Synchronism fine)
DB31, ... DBX98.1 (Synchronism coarse)
DB31, ... DBX99.1 (FS active)
Extended Functions
DB31, ...
DBX98.0 Fine synchronism
Signal state 1 or edge The positional deviation or velocity difference between the following spindle and its leading
change 0 1 spindle is within the "Fine synchronism" tolerance band.
change 1 0 spindle is not within the "Fine synchronism" tolerance band.
Note:
The signal is relevant only for the following spindle in synchronous operation.
Application example Clamping of workpiece in following spindle on transfer from the leading spindle: Clamping of
the workpiece is not initiated by the PLC user program until the spindles are sufficiently
synchronized.
Corresponding to .... DB31, ... DBX84.4 (Synchronous mode)
MD37210 $MA_COUPLE_POS_TOL_FINE (threshold value for "fine synchronism")
MD37230 $MA_COUPLE_VELO_TOL_FINE ("fine" speed tolerance)
DB31, ...
DBX98.1 Coarse synchronism
change 0 1 spindle is within the "Coarse synchronism" tolerance band.
Note:
change 1 0 spindle is not within the "Coarse synchronism" tolerance band.
Application example Clamping of workpiece in following spindle on transfer from the leading spindle: Clamping of
the workpiece is not initiated by the PLC user program until the spindles are sufficiently
synchronized.
MD37200 $MA_COUPLE_POS_TOL_COARSE (threshold value for "coarse synchronism")
MD37220 $MA_COUPLE_VELO_TOL_COARSE ("coarse" speed tolerance)
DB31, ...
DBX98.2 Actual value coupling
Signal state 1 or edge The actual-value coupling is active as the coupling type between the leading and following
change 0 1 spindles (see MD21310).
Note:
The signal is relevant only for the active following spindle in synchronous operation.
Signal state 0 or edge The setpoint coupling is active as the coupling type between the leading and following
change 1 0 spindles (see MD21310).
Extended Functions
DB31, ...
DBX98.2 Actual value coupling
Special cases, errors, .... In the case of faults/disturbances on the following spindle which result in cancellation of the
FS "servo enable", the coupling relationship between the FS and LS is reversed and switched
over to an actual-value coupling internally in the control under certain circumstances.
MD21310 $MC_COUPLING_MODE_1 (coupling type in synchr. spindle oper.)
DB31, ...
DBX98.4 Overlaid motion
Signal state 1 or edge The following spindle traverses an additional motional component which is overlaid on the
change 0 1 motion from the coupling with the leading spindle.
Examples of overlaid movement of FS:
- Activation of synchronous operation with defined angular offset between FS and LS
- Activation of synchronous operation with LS in rotation
- Alteration of transmission ratio when synchronous operation is selected
- Input of a new defined angular offset when synchronous operation is selected
- Traversal of FS with plus or minus traversing keys or handwheel in JOG when synchronous
operation is selected
As soon as the FS executes an overlaid movement, IS "Fine synchronism" or IS "Coarse
synchronism" (depending on threshold value) may be canceled immediately.
Note:
Signal state 0 or edge The following spindle does not traverse any additional motional component or this motion has
change 1 0 been terminated.
DB31, ...
DBX99.0 LS (leading spindle) active
Signal state 1 or edge The machine axis is currently active as the leading spindle.
change 0 1 Note:
The signal is relevant only in synchronous operation.
Signal state 0 or edge The machine axis is not currently active as the leading spindle.
change 1 0
Special cases, errors, ... In the case of faults/disturbances on the following spindle which result in cancellation of the
In this case, the leading spindle becomes the new, active following spindle (IS "FS active").
DB31, ... DBX99.1 (FS active)
Extended Functions
18.14 Memory Configuration (S7)
DB31, ...
DBX99.1 FS (following spindle) active
Signal state 1 or edge The machine axis is currently operating as the following spindle.
change 0 1 The following spindle thus follows the movements of the leading spindle in synchronous
operation in accordance with the transmission ratio.
Note:
The signal is relevant only in synchronous operation.
Signal state 0 or edge The machine axis is not currently operating as the following spindle.
change 1 0
Special cases, errors, ... In the case of faults/disturbances on the following spindle which result in cancellation of the
DB31, ... DBX99.0 (LS active)
18.14 Memory Configuration (S7)

18.15 Indexing Axes (T1)
DB31, ...
DBX76.6 Indexing axis in position
Signal state 1 or The signal is influenced according to the "Exact stop fine":
edge change 0 1 When "Exact stop fine" is achieved, the signal is set.
When exiting "Exact stop fine", the signal is reset.
The indexing axis is located on an indexing position.
The indexing axis has been positioned with instructions for "Coded Position".
Note:
If the "Exact stop fine" window is reached and the indexing axis is positioned on an indexing
position, the signal is enabled regardless of how the indexing position was reached.
Extended Functions
18.16 Tool Change (W3)
DB31, ...
DBX76.6 Indexing axis in position
Signal state 0 or The axis is not defined as an indexing axis.
edge change 1 0
The indexing axis is traversing:
DB31, ... DBX64.7/64.6 (Travel command+/-) is active.
The indexing axis is located at a position which is not an indexing position.
Examples:
In JOG mode after abortion of travel movement, e.g. with RESET
in Automatic mode: indexing axis has, for example, approached a selected position
controlled by an AC or DC instruction
The indexing axis has not been positioned with instructions for coded positions (CAC, CACP,
CACN, CDC, CIC) in automatic mode.
The "Servo enable" signal for the indexing axis has been canceled:
DB31, ... DBX2.1 (Servo enable)
Signal irrelevant for ... Axes that are not defined as indexing axes:
... MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB = 0
Application Tool magazine: Activation of a gripper for removing a tool from a magazine is triggered when the
example(s) indexing axis is in position:
DB31, ... DBX76.6 (indexing axis in position) = 1.
This must ensured by the PLC user program.
Special cases, errors, Notes:
... The axis positions entered in the indexing position table for the individual divisions can be changed
through zero offsets (including DRF).
The interface signal:
is then set to 1 when the actual position of the indexing axis matches the value entered in the index
table plus the offset.
If a DRF is applied to an indexing axis in AUTOMATIC mode, then interface signal "Indexing axis in
position" remains active even though the axis is no longer at an indexing position.
Corresponding to .... MD30500 $MA_INDEX_AX_ASSIGN_POS_TAB (axis is an indexing axis)
18.16 Tool Change (W3)

Extended Functions
18.17 Grinding-specific tool offset and tool monitoring (W4)
18.17 Grinding-specific tool offset and tool monitoring (W4)
DB31, ...
DBX83.3 Geometry monitoring
Edge evaluation: No Signal(s) updated: -
Signal state 1 or Error in grinding wheel geometry.
edge change 0 1 Note:
There is no further reaction to the response of this monitoring function.
Reactions deemed necessary must be programmed by the PLC user.
Signal state 0 or No error in grinding wheel geometry.
edge change 1 0
Application Grinding-specific tool monitoring
example(s)
DB31, ...
DBX83.6 Speed monitoring
Signal state 1 or Error in grinding wheel speed.
edge change 0 1 Note:
No further reaction to this signal state is programmed.
Reactions deemed necessary must be programmed by the PLC user.
Signal state 0 or No error in grinding wheel speed.
edge change 1 0
Application Grinding-specific tool monitoring
example(s)
DB31, ...
DBX84.1 GWPS active
Signal state 1 or Constant grinding wheel peripheral speed (GWPS) is active.
edge change 0 1 If GWPS is active, then all S value inputs from the PLC are interpreted as the grinding wheel
peripheral speed.
Signal state 0 or Constant grinding wheel peripheral speed (GWPS) is not active.
edge change 1 0
Application GWPS in all operating modes.
example(s)
Extended Functions
Appendix A
A.1 List of abbreviations
A
O Output
ADI4 (Analog drive interface for 4 axes)
AC Adaptive Control
ALM Active Line Module
ARM Rotating induction motor
AS PLC
ASCII American Standard Code for Information Interchange: American coding standard for
the exchange of information
ASIC Application-Specific Integrated Circuit: User switching circuit
ASUB Asynchronous subprogram
AUXFU Auxiliary Function: Auxiliary function
STL Statement List
UP User Program
B
BA Mode
BAG Mode group
BCD Binary Coded Decimals: Decimal numbers encoded in binary code
BERO Proximity limit switch with feedback oscillator
BI Binector Input
BICO Binector Connector
BIN BINary files: Binary files
BIOS Basic Input Output System
BCS Basic Coordinate System
BO Binector Output
OPI Operator Panel Interface
C
CAD Computer-Aided Design
CAM Computer-Aided Manufacturing
CC Compile Cycle: Compile cycles
Extended Functions
Appendix
C
CI Connector Input
CF Card Compact Flash Card
CNC Computerized Numerical Control: Computer-Supported Numerical Control
CO Connector Output
CoL Certificate of License
COM Communication
CPA Compiler Projecting Data: Configuring data of the compiler
CRT Cathode Ray Tube picture tube
CSB Central Service Board: PLC module
CU Control Unit
CP Communication Processor
CPU Central Processing Unit: Central processing unit
CR Carriage Return
CTS Clear To Send: Ready to send signal for serial data interfaces
CUTCOM Cutter radius Compensation: Tool radius compensation
D
DAC Digital-to-Analog Converter
DB Data Block (PLC)
DBB Data Block Byte (PLC)
DBD Data Block Double word (PLC)
DBW Data Block Word (PLC)
DBX Data block bit (PLC)
DDE Dynamic Data Exchange
DIN Deutsche Industrie Norm
DIO Data Input/Output: Data transfer display
DIR Directory: Directory
DLL Dynamic Link Library
DO Drive Object
DPM Dual Port Memory
DPR Dual Port RAM
DRAM Dynamic memory (non-buffered)
DRF Differential Resolver Function: Differential revolver function (handwheel)
DRIVE-CLiQ Drive Component Link with IQ
DRY Dry Run: Dry run feedrate
DSB Decoding Single Block: Decoding single block
DSC Dynamic Servo Control / Dynamic Stiffness Control
DW Data Word
DWORD Double Word (currently 32 bits)
Extended Functions
Appendix
I
I Input
I/O Input/Output
ENC Encoder: Actual value encoder
EFP Compact I/O module (PLC I/O module)
ESD Electrostatic Sensitive Devices
EMC ElectroMagnetic Compatibility
EN European standard
EnDat Encoder interface
EPROM Erasable Programmable Read Only Memory: Erasable, electrically programmable
read-only memory
ePS Network Services Services for Internet-based remote machine maintenance
EQN Designation for an absolute encoder with 2048 sine signals per revolution
ES Engineering System
ESR Extended Stop and Retract
ETC ETC key ">"; softkey bar extension in the same menu
F
FB Function Block (PLC)
FC Function Call: Function Block (PLC)
FEPROM Flash EPROM: Read and write memory
FIFO First In First Out: Memory that works without address specification and whose data is
read in the same order in which they was stored
FIPO Fine interpolator
FPU Floating Point Unit: Floating Point Unit
CRC Cutter Radius Compensation
FST Feed Stop: Feedrate stop
FBD Function Block Diagram (PLC programming method)
FW Firmware
G
GC Global Control (PROFIBUS: Broadcast telegram)
GEO Geometry, e.g. geometry axis
GIA Gear Interpolation dAta: Gear interpolation data
GND Signal Ground
GP Basic program (PLC)
GS Gear Stage
GSD Device master file for describing a PROFIBUS slave
Extended Functions
Appendix
G
GSDML Generic Station Description Markup Language: XML-based description language for
creating a GSD file
GUD Global User Data: Global user data
H
HEX Abbreviation for hexadecimal number
AuxF Auxiliary Function
HLA Hydraulic linear drive
HMI Human Machine Interface: SINUMERIK user interface
MSD Main Spindle Drive
HW Hardware
I
IBN Commissioning
ICA Interpolatory compensation
IM Interface Module Interconnection module
IMR Interface Module Receive: Interface module for receiving data
IMS Interface Module Send: Interface module for sending data
INC Increment: Increment
INI Initializing Data: Initializing data
IPO Interpolator
ISA Industry Standard Architecture
ISO International Standardization Organization
J
JOG Jogging: Setup mode
K
KV Gain factor of control loop
Kp Proportional gain
K Transformation ratio
LAD Ladder Diagram (PLC programming method)
Extended Functions
Appendix
L
LAI Logic Machine Axis Image: Logical machine axes image
LAN Local Area Network
LCD Liquid Crystal Display: Liquid crystal display
LED Light Emitting Diode: Light-emitting diode
LF Line Feed
PMS Position Measuring System
LR Position controller
LSB Least Significant Bit Least significant bit
LUD Local User Data: User data (local)
M
MAC Media Access Control
MAIN Main program: Main program (OB1, PLC)
MB Megabyte
MCI Motion Control Interface
MCIS Motion Control Information System
MCP Machine Control Panel: Machine control panel
MD Machine Data
MDA Manual Data Automatic: Manual input
MSGW Message Word
MCS Machine Coordinate System
MLFB Machine-readable product code
MM Motor Module
MPF Main Program File: Main program (NC)
MCP Machine Control Panel
N
NC Numerical Control: Numerical Control
NCK Numerical Control Kernel: NC kernel with block preparation, traversing range, etc.
NCU Numerical Control Unit: NCK hardware unit
NRK Name for the operating system of the NCK
IS Interface Signal
NURBS Non-Uniform Rational B-Spline
ZO Zero Offset
NX Numerical Extension: Axis expansion board
Extended Functions
Appendix
O
OB Organization block in the PLC
OEM Original Equipment Manufacturer
OP Operator Panel: Operating equipment
OPI Operator Panel Interface: Interface for connection to the operator panel
OPT Options: Options
OLP Optical Link Plug: Fiber optic bus connector
OSI Open Systems Interconnection: Standard for computer communications
P
PIQ Process Image Output
PII Process Image Input
PC Personal Computer
PCIN Name of the SW for data exchange with the controller
PCMCIA Personal Computer Memory Card International Association:
Plug-in memory card standardization
PCU PC Unit: PC box (computer unit)
PG Programming device
PKE Parameter identification: Part of a PIV
PIV Parameter identification: Value (parameterizing part of a PPO)
PLC Programmable Logic Control: Adaptation control
PN PROFINET
PNO PROFIBUS user organization
PO POWER ON
POU Program Organization Unit
POS Position/positioning
POSMO A Positioning Motor Actuator: Positioning motor
POSMO CA Positioning Motor Compact AC: Complete drive unit with integrated power and
control module as well as positioning unit and program memory; AC infeed
POSMO CD Positioning Motor Compact DC: Like CA but with DC infeed
POSMO SI Positioning Motor Servo Integrated: Positioning motor, DC infeed
PPO Parameter Process data Object: Cyclic data telegram for PROFIBUS DP
transmission and "Variable speed drives" profile
PPU Panel Processing Unit (central hardware for a panel-based CNC, e.g SINUMERIK
828D)
PROFIBUS Process Field Bus: Serial data bus
PRT Program Test
PSW Program control word
PTP Point-To-Point Point-To-Point
PUD Program global User Data: Program-global user variables
PZD Process data: Process data part of a PPO
Extended Functions
Appendix
Q
QEC Quadrant Error Compensation
R
RAM Random Access Memory: Read/write memory
REF REFerence point approach function
REPOS REPOSition function
RISC Reduced Instruction Set Computer: Type of processor with small instruction set and
ability to process instructions at high speed
ROV Rapid Override: Input correction
RP R Parameter, arithmetic parameter, predefined user variable
RPA R Parameter Active: Memory area on the NCK for R parameter numbers
RPY Roll Pitch Yaw: Rotation type of a coordinate system
RTLI Rapid Traverse Linear Interpolation: Linear interpolation during rapid traverse motion
RTS Request To Send: Control signal of serial data interfaces
RTCP Real Time Control Protocol
S
SA Synchronized Action
SBC Safe Brake Control: Safe Brake Control
SBL Single Block: Single block
SBR Subroutine: Subroutine (PLC)
SD Setting Data
SDB System Data Block
SEA Setting Data Active: Identifier (file type) for setting data
SERUPRO SEarch RUn by PROgram test: Search run by program test
SFB System Function Block
SFC System Function Call
SGE Safety-related input
SGA Safety-related output
SH Safe standstill
SIM Single Inline Module
SK Softkey
SKP Skip: Function for skipping a part program block
SLM Synchronous Linear Motor
SM Stepper Motor
SMC Sensor Module Cabinet Mounted
SME Sensor Module Externally Mounted
SMI Sensor Module Integrated
Extended Functions
Appendix
S
SPF Sub Routine File: Subprogram (NC)
PLC Programmable Logic Controller
SRAM Static RAM (non-volatile)
TNRC Tool Nose Radius Compensation
SRM Synchronous Rotary Motor
LEC Leadscrew Error Compensation
SSI Serial Synchronous Interface: Synchronous serial interface
SSL Block search
STW Control word
GWPS Grinding Wheel Peripheral Speed
SW Software
SYF System Files: System files
SYNACT SYNchronized ACTion: Synchronized Action
T
TB Terminal Board (SINAMICS)
TCP Tool Center Point: Tool tip
TCP/IP Transport Control Protocol / Internet Protocol
TCU Thin Client Unit
TEA Testing Data Active: Identifier for machine data
TIA Totally Integrated Automation
TM Terminal Module (SINAMICS)
TO Tool Offset: Tool offset
TOA Tool Offset Active: Identifier (file type) for tool offsets
TRANSMIT Transform Milling Into Turning: Coordination transformation for milling operations on
a lathe
TTL Transistor-Transistor Logic (interface type)
TZ Technology cycle
U
UFR User Frame: Zero Offset
SR Subprogram
USB Universal Serial Bus
UPS Uninterruptible Power Supply
Extended Functions
Appendix
V
VDI Internal communication interface between NCK and PLC
VDI Verein Deutscher Ingenieure [Association of German Engineers]
VDE Verband Deutscher Elektrotechniker [Association of German Electrical Engineers]
VI Voltage Input
VO Voltage Output
FDD Feed Drive
W
SAR Smooth Approach and Retraction
WCS Workpiece Coordinate System
T Tool
TLC Tool Length Compensation
WOP Workshop-Oriented Programming
WPD Workpiece Directory: Workpiece directory
TRC Tool Radius Compensation
T Tool
TO Tool Offset
TM Tool Management
TC Tool change
X
XML Extensible Markup Language
Z
ZOA Zero Offset Active: Identifier for zero offsets
ZSW Status word (of drive)
Extended Functions
Appendix
A.2 Overview
A.2 Overview
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Extended Functions
Glossary
Absolute dimensions
A destination for an axis motion is defined by a dimension that refers to the origin of the
currently active coordinate system. See Incremental dimension
Acceleration with jerk limitation

In order to optimize the acceleration response of the machine whilst simultaneously
protecting the mechanical components, it is possible to switch over in the machining program
between abrupt acceleration and continuous (jerk-free) acceleration.
Address
An address is the identifier for a certain operand or operand range, e.g. input, output, etc.
Alarms
All messages and alarms are displayed on the operator panel in plain text with date and
time and the corresponding symbol for the cancel criterion. Alarms and messages are
displayed separately.
1. Alarms and messages in the part program:
Alarms and messages can be displayed in plain text directly from the part program.
2. Alarms and messages from the PLC:
Alarms and messages for the machine can be displayed in plain text from the PLC
program. No additional function block packages are required for this purpose.
Archiving
Reading out of files and/or directories on an external memory device.
Asynchronous subprogram
Part program that can be started asynchronously to (independently of) the current program
status using an interrupt signal (e.g. "Rapid NC input" signal).
Automatic
Operating mode of the controller (block sequence operation according to DIN): Operating
mode for NC systems in which a subprogram is selected and executed continuously.
Extended Functions
Glossary
Auxiliary functions
Auxiliary functions enable part programs to transfer parameters to the PLC, which
then trigger reactions defined by the machine manufacturer.
Axes
In accordance with their functional scope, the CNC axes are subdivided into:
Axes: Interpolating path axes
Auxiliary axes: Non-interpolating feed and positioning axes with an axis-specific feedrate.
Auxiliary axes are not involved in actual machining, e.g. tool feeder, tool magazine.
Axis address
See Axis name
Axis name
To ensure clear identification, all channel and machine axes of the control system must be
designated with unique names in the channel and control system. The geometry axes are
called X, Y, Z. The rotary axes rotating around the geometry axes are called A, B, C.
Backlash compensation
Compensation for a mechanical machine backlash, e.g. backlash on reversal for ball screws.
Backlash compensation can be entered separately for each axis.
Backup battery
The backup battery ensures that the user program in the CPU is stored so that it is safe
from power failure and so that specified data areas and bit memory, timers and counters are
stored retentively.
Basic axis
Axis whose setpoint or actual value position forms the basis of the calculation of a
compensation value.
Basic Coordinate System

Cartesian coordinate system which is mapped by transformation onto the machine
coordinate system.
The programmer uses axis names of the basic coordinate system in the part program. The
basic coordinate system exists parallel to the machine coordinate system if no
transformation is active. The difference lies in the axis names.
Extended Functions
Glossary
Baud rate
Rate of data transfer (bits/s).
Blank
Workpiece as it is before it is machined.
Block
"Block" is the term given to any files required for creating and processing programs.
Block search
For debugging purposes or following a program abort, the "Block search" function can be
used to select any location in the part program at which the program is to be started or
resumed.
Booting
Loading the system program after power ON.
C axis
Axis around which the tool spindle describes a controlled rotational and positioning motion.
C spline
The C spline is the most well-known and widely used spline. The transitions at the
interpolation points are continuous, both tangentially and in terms of curvature. 3rd order
polynomials are used.
Channel
A channel is characterized by the fact that it can process a part program independently of
other channels. A channel exclusively controls the axes and spindles assigned to it. Part
program runs of different channels can be coordinated through synchronization.
Circular interpolation
The tool moves on a circle between specified points on the contour at a given feedrate,
and the workpiece is thereby machined.
CNC
See NC
Extended Functions
Glossary
COM
Component of the NC for the implementation and coordination of communication.
Compensation axis
Axis with a setpoint or actual value modified by the compensation value
Compensation table
Table containing interpolation points. It provides the compensation values of the
compensation axis for selected positions on the basic axis.
Compensation value
Difference between the axis position measured by the encoder and the desired, programmed
axis position.
Continuous-path mode
The objective of continuous-path mode is to avoid substantial deceleration of the path
axes at the part program block boundaries and to change to the next block at as close to the
same path velocity as possible.
Contour
Contour of the workpiece
Contour monitoring
The following error is monitored within a definable tolerance band as a measure of contour
accuracy. An unacceptably high following error can cause the drive to become overloaded,
for example. In such cases, an alarm is output and the axes are stopped.
Coordinate system
See Machine coordinate system, Workpiece coordinate system
CPU
Central processing unit, see PLC
Curvature
The curvature k of a contour is the inverse of radius r of the nestling circle in a contour point
(k = 1/r).
Extended Functions
Glossary
Cycles
Protected subprograms for execution of repetitive machining operations on the workpiece.
Data block
1. Data unit of the PLC that HIGHSTEP programs can access.
2. Data unit of the NC: Data modules contain data definitions for global user data. This
data can be initialized directly when it is defined.
Data word
Two-byte data unit within a data block.
Diagnostics
1. Operating area of the controller.
2. The controller has a self-diagnostics program as well as test functions for servicing
purposes: status, alarm, and service displays
Dimensions specification, metric and inches

Position and pitch values can be programmed in inches in the machining program.
Irrespective of the programmable dimensions (G70/G71), the controller is set to a basic
system.
DRF
Differential Resolver Function: NC function which generates an incremental zero offset in
Automatic mode in conjunction with an electronic handwheel.
Drive
The drive is the unit of the CNC that performs the speed and torque control based on the
settings of the NC.
Dynamic feedforward control

Inaccuracies in the contour due to following errors can be practically eliminated using
dynamic, acceleration-dependent feedforward control. This results in excellent machining
accuracy even at high path velocities. Feedforward control can be selected and
deselected on an axis-specific basis via the part program.
Extended Functions
Glossary
Editor
The editor makes it possible to create, edit, extend, join, and import programs/texts/program
blocks.
Exact stop
When an exact stop statement is programmed, the position specified in a block is
approached exactly and, if necessary, very slowly. To reduce the approach time, exact
stop limits are defined for rapid traverse and feed.
Exact stop limit

When all path axes reach their exact stop limits, the controller responds as if it had reached
its precise destination point. A block advance of the part program occurs.
External zero offset

Zero offset specified by the PLC.
Fast retraction from the contour

When an interrupt occurs, a motion can be initiated via the CNC machining program,
enabling the tool to be quickly retracted from the workpiece contour that is currently being
machined. The retraction angle and the distance retracted can also be parameterized. An
interrupt routine can also be executed following the fast retraction.
Feed override
The programmed velocity is overriden by the current velocity setting made via the machine
control panel or from the PLC (0 to 200%). The feedrate can also be corrected by a
programmable percentage factor (1 to 200%) in the machining program.
Finished-part contour
Contour of the finished workpiece. See Raw part.
Fixed machine point

Point that is uniquely defined by the machine tool, e.g. machine reference point.
Fixed-point approach
Machine tools can approach fixed points such as a tool change point, loading point, pallet
change point, etc. in a defined way. The coordinates of these points are stored in the
controller. The controller moves the relevant axes in rapid traverse, whenever possible.
Extended Functions
Glossary
Frame
A frame is an arithmetic rule that transforms one Cartesian coordinate system into another
Cartesian coordinate system. A frame contains the following components: zero offset,
rotation, scaling, mirroring.
Geometry
Description of a workpiece in the workpiece coordinate system.
Geometry axis
The geometry axes form the 2 or 3-dimensional workpiece coordinate system in which, in
part programs, the geometry of the workpiece is programmed.
Ground
Ground is taken as the total of all linked inactive parts of a device which will not become live
with a dangerous contact voltage even in the event of a malfunction.
Helical interpolation
The helical interpolation function is ideal for machining internal and external threads using
form milling cutters and for milling lubrication grooves.
The helix comprises two motions:
Circular motion in one plane
A linear motion perpendicular to this plane
High-level CNC language

The high-level language offers: user-defined variables, system variables, macro
techniques.
High-speed digital inputs/outputs

The digital inputs can be used for example to start fast CNC program routines (interrupt
routines). High-speed, program-driven switching functions can be initiated via the digital
CNC outputs
HIGHSTEP
Summary of programming options for PLCs of the AS300/AS400 system.
Extended Functions
Glossary
HW Config
SIMATIC S7 tool for the configuration and parameterization of hardware components within
an S7 project
Identifier
In accordance with DIN 66025, words are supplemented using identifiers (names) for
variables (arithmetic variables, system variables, user variables), subprograms, key words,
and words with multiple address letters. These supplements have the same meaning as the
words with respect to block format. Identifiers must be unique. It is not permissible to use the
same identifier for different objects.
Inch measuring system

Measuring system which defines distances in inches and fractions of inches.
Inclined surface machining

Drilling and milling operations on workpiece surfaces that do not lie in the coordinate planes
of the machine can be performed easily using the function "inclined-surface machining".
Increment
Travel path length specification based on number of increments. The number of increments
can be stored as setting data or be selected by means of a suitably labeled key (i.e. 10,
100, 1000, 10000).
Incremental dimension
Also incremental dimension: A destination for axis traversal is defined by a distance to be
covered and a direction referenced to a point already reached. See Absolute dimension.
Intermediate blocks
Motions with selected tool offset (G41/G42) may be interrupted by a limited number of
intermediate blocks (blocks without axis motions in the offset plane), whereby the tool offset
can still be correctly compensated for. The permissible number of intermediate blocks which
the controller reads ahead can be set in system parameters.
Interpolator
Logic unit of the NCK that defines intermediate values for the motions to be carried out in
individual axes based on information on the end positions specified in the part program.
Extended Functions
Glossary
Interpolatory compensation
Interpolatory compensation is a tool that enables manufacturing-related leadscrew error and
measuring system error compensations (SSFK, MSFK).
Interrupt routine
Interrupt routines are special subprograms that can be started by events (external signals)
in the machining process. A part program block which is currently being worked through is
interrupted and the position of the axes at the point of interruption is automatically saved.
Inverse-time feedrate
The time required for the path of a block to be traversed can also be programmed for the
axis motion instead of the feed velocity (G93).
JOG
Control operating mode (setup mode): In JOG mode, the machine can be set up. Individual
axes and spindles can be traversed in JOG mode by means of the direction keys. Additional
functions in JOG mode include: Reference point approach, Repos, and Preset (set
actual value).
Key switch
The key switch on the machine control panel has four positions that are assigned functions
by the operating system of the controller. The key switch has three different colored keys
that can be removed in the specified positions.
Keywords
Words with specified notation that have a defined meaning in the programming language for
part programs.
K
Transformation ratio
KV
Servo gain factor, a control variable in a control loop.
Leading axis
The leading axis is the gantry axis that exists from the point of view of the operator and
programmer and, thus, can be influenced like a standard NC axis.
Extended Functions
Glossary
Leadscrew error compensation

Compensation for the mechanical inaccuracies of a leadscrew participating in the feed. The
controller uses stored deviation values for the compensation.
Limit speed
Maximum/minimum (spindle) speed: The maximum speed of a spindle can be limited by
specifying machine data, the PLC or setting data.
Linear axis
In contrast to a rotary axis, a linear axis describes a straight line.
Linear interpolation
The tool travels along a straight line to the destination point while machining the workpiece.
Load memory
The load memory is the same as the working memory for the CPU 314 of the PLC.
Look Ahead
The Look Ahead function is used to achieve an optimal machining speed by looking ahead
over an assignable number of traversing blocks.
Machine axes
Physically existent axes on the machine tool.
Machine control panel

An operator panel on a machine tool with operating elements such as keys, rotary switches,
etc., and simple indicators such as LEDs. It is used to directly influence the machine tool via
the PLC.
Machine coordinate system

A coordinate system, which is related to the axes of the machine tool.
Machine zero
Fixed point of the machine tool to which all (derived) measuring systems can be traced back.
Extended Functions
Glossary
Machining channel
A channel structure can be used to shorten idle times by means of parallel motion
sequences, e.g. moving a loading gantry simultaneously with machining. Here, a CNC
channel must be regarded as a separate CNC control system with decoding, block
preparation and interpolation.
Macro techniques
Grouping of a set of statements under a single identifier. The identifier represents the set of
consolidated statements in the program.
Main block
A block prefixed by ":" introductory block, containing all the parameters required to start
execution of a -> part program.
Main program
The term "main program" has its origins during the time when part programs were split
strictly into main and subprograms. This strict division no longer exists with today's
SINUMERIK NC language. In principle, any part program in the channel can be selected and
started. It then runs through in program level 0 (main program level). Further part
programs or cycles as subprograms can be called up in the main program.
MDA
Control operating mode: Manual Data Automatic. In the MDA mode, individual program
blocks or block sequences with no reference to a main program or subprogram can be input
and executed immediately afterwards through actuation of the NC start key.
Messages
All messages programmed in the part program and alarms detected by the system are
displayed on the operator panel in plain text with date and time and the corresponding
symbol for the cancel criterion. Alarms and messages are displayed separately.
Metric measuring system

Standardized system of units: For length, e.g. mm (millimeters), m (meters).
Mirroring
Mirroring reverses the signs of the coordinate values of a contour, with respect to an axis. It
is possible to mirror with respect to more than one axis at a time.
Extended Functions
Glossary
Mode
An operating concept on a SINUMERIK controller. The following modes are defined: Jog,
MDA, Automatic.
Mode group
Axes and spindles that are technologically related can be combined into one mode group.
Axes/spindles of a mode group can be controlled by one or more channels. The same
mode type is always assigned to the channels of the mode group.
NC
Numerical Control: Numerical control (NC) includes all components of machine tool control:
NCK, PLC, HMI, COM.
Note
A more correct term for SINUMERIK controllers would be: Computerized Numerical Control
NCK
Numerical Control Kernel: Component of NC that executes the part programs and
basically coordinates the motion operations for the machine tool.
Network
A network is the connection of multiple S7-300 and other end devices, e.g. a programming
device via a connecting cable. A data exchange takes place over the network between the
connected devices.
NRK
Numeric robotic kernel (operating system of NCK)
NURBS
The motion control and path interpolation that occurs within the controller is performed based
on NURBS (Non Uniform Rational B-Splines). This provides a uniform procedure for all
internal interpolations.
OEM
The scope for implementing individual solutions (OEM applications) has been provided for
machine manufacturers, who wish to create their own user interface or integrate technology-
specific functions in the controller.
Extended Functions
Glossary
Offset memory
Data range in the control, in which the tool offset data is stored.
Oriented spindle stop

Stops the workpiece spindle in a specified angular position, e.g. in order to perform
additional machining at a particular location.
Oriented tool retraction

RETTOOL: If machining is interrupted (e.g. when a tool breaks), a program command can be
used to retract the tool in a user-specified orientation by a defined distance.
Overall reset
In the event of an overall reset, the following memories of the CPU are deleted:
Working memory
Read/write area of load memory
System memory
Backup memory
Override
Manual or programmable control feature which enables the user to override programmed
feedrates or speeds in order to adapt them to a specific workpiece or material.
Part program
Series of statements to the NC that act in concert to produce a particular workpiece.
Likewise, this term applies to execution of a particular machining operation on a given raw
part.
Part program block

Part of a part program that is demarcated by a line feed. There are two types: main
blocks and subblocks.
Part program management

Part program management can be organized by workpieces. The size of the user memory
determines the number of programs and the amount of data that can be managed. Each file
(programs and data) can be given a name consisting of a maximum of 24 alphanumeric
characters.
Extended Functions
Glossary
Path axis
Path axes include all machining axes of the channel that are controlled by the
interpolator in such a way that they start, accelerate, stop, and reach their end point
simultaneously.
Path feedrate
Path feed affects path axes. It represents the geometric sum of the feedrates of the
geometry axes involved.
Path velocity
The maximum programmable path velocity depends on the input resolution. For example,
with a resolution of 0.1 mm the maximum programmable path velocity is 1000 m/min.
PCIN data transfer program

PCIN is an auxiliary program for sending and receiving CNC user data (e.g. part programs,
tool offsets, etc.) via a serial interface. The PCIN program can run in MS-DOS on standard
industrial PCs.
Peripheral module
I/O modules represent the link between the CPU and the process.
I/O modules are:
Digital input/output modules
Analog input/output modules
Simulator modules
PLC
Programmable Logic Controller: Programmable logic controller. Component of NC:
Programmable control for processing the control logic of the machine tool.
PLC program memory

SINUMERIK 840D sl: The PLC user program, the user data and the basic PLC program are
stored together in the PLC user memory.
PLC programming
The PLC is programmed using the STEP 7 software. The STEP 7 programming software is
based on the WINDOWS standard operating system and contains the STEP 5 programming
functions with innovative enhancements.
Extended Functions
Glossary
Polar coordinates
A coordinate system which defines the position of a point on a plane in terms of its distance
from the origin and the angle formed by the radius vector with a defined axis.
Polynomial interpolation
Polynomial interpolation enables a wide variety of curve characteristics to be generated,
such as straight line, parabolic, exponential functions (SINUMERIK 840D sl).
Positioning axis
Axis that performs an auxiliary motion on a machine tool (e.g. tool magazine, pallet
transport). Positioning axes are axes that do not interpolate with path axes.
Position-time cams
The term "position-time cam" refers to a pair of software cams that can supply a pulse of a
certain duration at a defined axis position.
Pre-coincidence
Block change occurs already when the path distance approaches an amount equal to a
specifiable delta of the end position.
Program block
Program blocks contain the main program and subprograms of part programs.
Program level
A part program started in the channel runs as a main program on program level 0 (main
program level). Any part program called up in the main program runs as a subprogram on
a program level 1 ... n of its own.
Programmable frames
Programmable frames enable dynamic definition of new coordinate system output points
while the part program is being executed. A distinction is made between absolute definition
using a new frame and additive definition with reference to an existing starting point.
Extended Functions
Glossary
Programmable logic controller

Programmable logic controllers (PLCs) are electronic controllers, the function of which is
stored as a program in the control unit. This means that the layout and wiring of the device
do not depend on the function of the controller. The programmable logic control has the
same structure as a computer; it consists of a CPU (central module) with memory,
input/output modules and an internal bus system. The peripherals and the programming
language are matched to the requirements of the control technology.
Programmable working area limitation

Limitation of the motion space of the tool to a space defined by programmed limitations.
Programming key
Characters and character strings that have a defined meaning in the programming language
for part programs.
Protection zone
Three-dimensional zone within the working area into which the tool tip must not pass.
Quadrant error compensation

Contour errors at quadrant transitions, which arise as a result of changing friction conditions
on the guideways, can be virtually entirely eliminated with the quadrant error compensation.
Parameterization of the quadrant error compensation is performed by means of a circuit test.
R parameters
Arithmetic parameter that can be set or queried by the programmer of the part program for
any purpose in the program.
Rapid traverse
The highest traverse rate of an axis. For example, rapid traverse is used when the tool
approaches the workpiece contour from a resting position or when the tool is retracted
from the workpiece contour. The rapid traverse velocity is set on a machine-specific basis
using a machine data element.
Reference point
Machine tool position that the measuring system of the machine axes references.
Rotary axis
Rotary axes apply a workpiece or tool rotation to a defined angular position.
Extended Functions
Glossary
Rotation
Component of a frame that defines a rotation of the coordinate system around a particular
angle.
Rounding axis
Rounding axes rotate a workpiece or tool to an angular position corresponding to an
indexing grid. When a grid index is reached, the rounding axis is "in position".
RS-232-C
Serial interface for data input/output. Machining programs as well as manufacturer and user
data can be loaded and saved via this interface.
Safety functions
The controller is equipped with permanently active monitoring functions that detect faults in
the CNC, the PLC, and the machine in a timely manner so that damage to the
workpiece, tool, or machine is largely prevented. In the event of a fault, the machining
operation is interrupted and the drives stopped. The cause of the malfunction is logged and
output as an alarm. At the same time, the PLC is notified that a CNC alarm has been
triggered.
Scaling
Component of a frame that implements axis-specific scale modifications.
Setting data
Data which communicates the properties of the machine tool to the NC as defined by the
system software.
Softkey
A key, whose name appears on an area of the screen. The choice of softkeys displayed is
dynamically adapted to the operating situation. The freely assignable function keys
(softkeys) are assigned defined functions in the software.

Software limit switches limit the traversing range of an axis and prevent an abrupt stop of the
slide at the hardware limit switch. Two value pairs can be specified for each axis and
activated separately by means of the PLC.
Extended Functions
Glossary
Spline interpolation
With spline interpolation, the controller can generate a smooth curve characteristic from only
a few specified interpolation points of a set contour.
Standard cycles
Standard cycles are provided for machining operations which are frequently repeated:
For the drilling/milling technology
For turning technology
The available cycles are listed in the "Cycle support" menu in the "Program" operating area.
Once the desired machining cycle has been selected, the parameters required for assigning
values are displayed in plain text.
Subblock
Block preceded by "N" containing information for a sequence, e.g. positional data.
Subprogram
The term "subprogram" has its origins during the time when part programs were split strictly
into main and subprograms. This strict division no longer exists with today's SINUMERIK
NC language. In principle, any part program or any cycle can be called up as a
subprogram within another part program. It then runs through in the next program level
(x+1) (subprogram level (x+1)).
Synchronization
Statements in part programs for coordination of sequences in different channels at
certain machining points.
Synchronized actions
1. Auxiliary function output
During workpiece machining, technological functions ( auxiliary functions) can be output
from the CNC program to the PLC. For example, these auxiliary functions are used to
control additional equipment for the machine tool, such as quills, grabbers, clamping
chucks, etc.
2. Fast auxiliary function output
For time-critical switching functions, the acknowledgement times for the auxiliary
functions can be minimized and unnecessary hold points in the machining process can
be avoided.
Extended Functions
Glossary
Synchronized axes
Synchronized axes take the same time to traverse their path as the geometry axes take for
their path.
Synchronized axis
A synchronized axis is the gantry axis whose set position is continuously derived from the
motion of the leading axis and is, thus, moved synchronously with the leading axis. From
the point of view of the programmer and operator, the synchronized axis "does not exist".
System memory
The system memory is a memory in the CPU in which the following data is stored:
Data required by the operating system
The operands timers, counters, markers
System variable
A variable that exists without any input from the programmer of a part program. It is
defined by a data type and the variable name preceded by the character $. See User-
defined variable.
Tapping without compensating chuck

This function allows threads to be tapped without a compensating chuck. By using the
interpolating method of the spindle as a rotary axis and the drilling axis, threads can be cut to
a precise final drilling depth, e.g. for blind hole threads (requirement: spindles in axis
operation).
Text editor
See Editor
TOA area
The TOA area includes all tool and magazine data. By default, this area coincides with the
channel area with regard to the access of the data. However, machine data can be used to
specify that multiple channels share one TOA unit so that common tool management data
is then available to these channels.
TOA unit
Each TOA area can have more than one TOA unit. The number of possible TOA units is
limited by the maximum number of active channels. A TOA unit includes exactly one tool
data block and one magazine data block. In addition, a TOA unit can also contain a
toolholder data block (optional).
Extended Functions
Glossary
Tool
Active part on the machine tool that implements machining (e.g. turning tool, milling tool, drill,
LASER beam, etc.).
Tool nose radius compensation

Contour programming assumes that the tool is pointed. Because this is not actually the case
in practice, the curvature radius of the tool used must be communicated to the controller
which then takes it into account. The curvature center is maintained equidistantly around the
contour, offset by the curvature radius.
Tool offset
Consideration of the tool dimensions in calculating the path.
Tool radius compensation

To directly program a desired workpiece contour, the control must traverse an equistant
path to the programmed contour taking into account the radius of the tool that is being used
(G41/G42).
Transformation
Additive or absolute zero offset of an axis.
Travel range
The maximum permissible travel range for linear axes is 9 decades. The absolute value
depends on the selected input and position control resolution and the unit of measurement
(inch or metric).
User interface
The user interface (UI) is the display medium for a CNC in the form of a screen. It features
horizontal and vertical softkeys.
User memory
All programs and data, such as part programs, subprograms, comments, tool offsets, and
zero offsets/frames, as well as channel and program user data, can be stored in the shared
CNC user memory.
Extended Functions
Glossary
User program
User programs for the S7-300 automation systems are created using the programming
language STEP 7. The user program has a modular layout and consists of individual blocks.
The basic block types are:
Code blocks
These blocks contain the STEP 7 commands.
Data blocks
These blocks contain constants and variables for the STEP 7 program.
User-defined variable
Users can declare their own variables for any purpose in the part program or data block
(global user data). A definition contains a data type specification and the variable name. See
System variable.
Variable definition
A variable definition includes the specification of a data type and a variable name. The
variable names can be used to access the value of the variables.
Velocity control
In order to achieve an acceptable traverse rate in the case of very slight motions per block,
an anticipatory evaluation over several blocks ( Look Ahead) can be specified.
WinSCP
WinSCP is a freely available open source program for Windows for the transfer of files.
Working area
Three-dimensional zone into which the tool tip can be moved on account of the physical
design of the machine tool. See Protection zone.
Working area limitation

With the aid of the working area limitation, the traversing range of the axes can be further
restricted in addition to the limit switches. One value pair per axis may be used to describe
the protected working area.
Working memory
The working memory is a RAM in the CPU that the processor accesses when processing
the application program.
Extended Functions
Glossary
Workpiece
Part to be made/machined by the machine tool.
Workpiece contour
Set contour of the workpiece to be created or machined.
Workpiece coordinate system

The workpiece coordinate system has its starting point in the workpiece zero-point. In
machining operations programmed in the workpiece coordinate system, the dimensions and
directions refer to this system.
Workpiece zero
The workpiece zero is the starting point for the workpiece coordinate system. It is defined
in terms of distances to the machine zero.
Zero offset
Specifies a new reference point for a coordinate system through reference to an existing
zero point and a frame.
1. Settable
A configurable number of settable zero offsets are available for each CNC axis. The
offsets - which are selected by means of G functions - take effect alternatively.
2. External
In addition to all the offsets which define the position of the workpiece zero, an external
zero offset can be overridden by means of the handwheel (DRF offset) or from the PLC.
3. Programmable
Zero offsets can be programmed for all path and positioning axes using the TRANS
statement.
Extended Functions
Index
$AN_CEC_OUTPUT_AXIS, 248
$AN_CEC_STEP, 248
$AN_LAI_AX_IS_AXCTAX, 111
$AN_LAI_AX_IS_LEADLINKAX, 111
$
$AN_LAI_AX_IS_LINKAX, 111
$A_DP_IN_CONF, 59 $AN_LAI_AX_TO_IPO_NC_CHANAX, 111
$A_DP_IN_STATE, 60 $AN_LAI_AX_TO_MACHAX, 111
$A_DP_IN_VALID, 60 $AN_REBOOT_DELAY_TIME, 300
$A_DP_OUT_CONF, 59 $P_COUP_OFFS, 726
$A_DP_OUT_STATE, 60 $P_ISTEST, 317
$A_DP_OUT_VALID, 60 $VA_COUP_OFFS, 726
$A_DPx_IN, 58
$A_DPx_OUT, 58
$A_IN, 31 1
$A_INA, 27
103lp, 110
$A_INCO, 45
1dimensional
$A_OUT, 32
Setpoint selection ($AC_MEAS_TYPE = 19),
$A_OUT[n], 548
$A_OUTA, 39
$A_PBx_IN, 48
2
$A_PBx_OUT, 48
$AA_ACT_INDEX_AX_POS_NO, 779 2dimensional
$AA_COUP_ACT, 726 Setpoint selection ($AC_MEAS_TYPE = 20),
$AA_COUP_OFFS, 726
$AA_ENC_COMP, 240
$AA_ENC_COMP_IS_MODULO, 241 3
$AA_ENC_COMP_MAX, 240
32402, 746
$AA_ENC_COMP_MIN, 240
39lp, 110
$AA_ENC_COMP_STEP, 240
3D Probe, 458
$AA_FIX_POINT_ACT, 188
3dimensional
$AA_FIX_POINT_SELECTED, 188
Setpoint selection ($AC_MEAS_TYPE = 21),
$AA_G0MODE, 608
$AA_ISTEST, 317
$AA_MOTEND, 625
4
$AA_PROG_INDEX_AX_POS_NO, 779
$AC_AXCTSWA, 111 42lp, 110
$AC_AXCTSWE, 111
$AC_ISTEST, 317
$AC_RETPOINT, 691 A
$AN_AXCTAS, 111
Acceleration, 212
$AN_AXCTSWA, 111
Acceleration characteristic, 569
$AN_CEC, 248
Acknowledgement of manual stroke initiation, 893
$AN_CEC_DIRECTION, 249
Acknowledgement of stopped status, 896
$AN_CEC_INPUT_AXIS, 248
ACN, 689
$AN_CEC_IS_MODULO, 249
ACP, 689
$AN_CEC_MAX, 248
Activation, 398
$AN_CEC_MIN, 248
Activation methods, 712
$AN_CEC_MULT_BY_TABLE, 249
Activation of coupling, 712
Extended Functions
Index
Active file system, 756 Geometry axis in rotated frame, 337

Active infeed axes, 901 Release axis container rotation, 333
Active/passive operating mode, 854 Requirements, 321
Active/passive operating mode of control unit, 854 Time of release, 332
Actual value coupling, 904 without preprocessing stop, 333
Actual value for analog NCK inputs, 845 Axis replacement via PLC, 631
Actual value for digital NCK inputs, 844 Axis types
All transformations, 415 For positioning axes, 603
Alter reversal point, 899 Axis/spindle interchange, 306
Alternate interface, 567 Axis/spindle replacement, 886
Ambiguity in position AxReset, 895
Examples, 403 AxResume, 895
Ambiguity in rotary axis position AxStop active, 896
Example, 404 AXTOCHAN, 338
Angular offset POSFS, 713
Applications, 387
Approaching a fixed point, 797 B
in JOG, 183
Backlash, 233
With G75, 183
-Compensation, dynamic, 234
ASCALE, 696
-Compensation, mechanical, 232
Assign feedrate using the programmed axis name of a
Dynamic, 234
positioning axis, 897
Mechanical, 231
ATRANS, 696
Bidirectional probe, 443
Automatic axis replacement with GETD, 328
Block change
Automatically activated pre-initiation time, 568
Positioning axis type 1, 621
Autonomous singleaxis operations
NCK reactions,
Block search, 571
PLC actions,
AxAlarm, 896
AXCTSWE, 110
C
AXCTSWEC, 110
AXCTSWED, 110 Calculated frame, 456
Axes Calculation method, 461
for auxiliary movements, 599 Cam activation, 890
Axial reset has been performed, 896 Cam signals
Axial stop alarm for this axis, 896 Hardware assignment, 548
axis linked output, 539
Basic, 236 Minus, 547
Compensation, 236 Plus, 547
Axis Separate output, 536
-interpolator, 606 Timer-controlled output, 549
Axis configuration, 387 Cams active, 890
Axis container, 270 Cartesian manual travel, 405
-Identifier, 102 Cartesian PTP travel, 398
Axis container rotation active, 857 STAT address, 401
Axis control passed to PLC, 896 TU address, 402
Axis ready, 857 CC-Bindings, 61
Axis replacement, 320 Chained transformations, 429
automatically generated GET/GETD, 327 Activating, 389
Axis in another channel, 321 Deactivation, 389
Axis replacement via synchronized actions, 338 Example, 427
Axis types, 320 Number, 388
Extended Functions
Index
Persistent transformation, 390 DBB102, 859

Special points to be noted, 389 DBB122, 837
Chaining direction, 388 DBB122 ..., 32
Chaining rule, 807 DBB123, 838
Changing the assignment, 414 DBB123 ...,
Channel, 602 DBB124, 837
synchronization, 308 DBB125, 838
Channel axis, 320 DBB126, 837
Channel axis identifier, 268 DBB127, 838
Channel number geometry axis for handwheel 1, 2, DBB128, 837
3, 858 DBB129, 838
Characteristics, 413 DBB130, 838
Clamping protection zone, 590 DBB130 ..., 34
CLEAR, 308 DBB131, 838
CLEARM, 309 DBB131 ..., 33
COARSEA, 618 DBB132, 839
Coded positions, 774 DBB132 ..., 33
Commands MEAS, MEAW, 444 DBB133, 839
Comparator inputs, 45 DBB133 ..., 34
Compensation DBB134, 838
Angularity error, 243 DBB135, 838
Following error, 278 DBB136, 839
Interpolatory, 235 DBB137, 839
Leadscrew error, 238 DBB138, 838
Measuring system error, 238 DBB139, 838
Sag, 243 DBB140, 839
Concurrent positioning axes DBB141, 839
start from the PLC, 631 DBB142, 838
Continuous dressing, 816 DBB143, 838
Continuous operation, 152 DBB144, 839
Continuous travel, 148 DBB145, 839
Contour handwheel, 178 DBB146, 840
Control unit requests active operating mode, 853 DBB147, 840
Control unit switchover disable, 853 DBB148 -163, 840
Conversion into another coordinate system, 457 DBB166, 841
Corner C1 - C4 ($AC_MEAS_TYPE = 4, 5, 6, 7), 470 DBB167, 841
Corner measurement C1, 471 DBB168, 842
coupling DBB170 -185, 842
Define new, 721 DBB186 ..., 34
Fixed configuration, 721 DBB186-189, 844
Coupling options, 707 DBB190-193, 845
CT, 110 DBB194 -209, 845
Cut-to-cut time, 796 DBB210 - 225, 41
Cylinder generated surface, 348 DBB210 -225, 845
DBB4, 838
DBB5, 838
D DBB6, 839
DBB60, 844
DB10
DBB64, 845
DBB0, 837
DBB7, 839
DBB1, 838
DBB97, 858
DBB100, 859
DBB98, 858
DBB101, 859
Extended Functions
Index
DBB99, 858 DBX15.0, 19.0, 23.0, 865

DBW148-162, 38 DBX16.0-2, 865
DBW170 , DBX16.0-5, 864
DBW194-208, 38 DBX16.4, 862
DBX100.0-4, 156 DBX16.5, 862
DBX100.6, 860 DBX16.6, 863
DBX100.7, 860 DBX16.7, 863
DBX101.0-4, 156 DBX17.6, 864
DBX101.6, 860 DBX19.0, 159
DBX101.7, 860 DBX20.0-2, 865
DBX102.0-4, 156 DBX20.0-5, 864
DBX102.6, 860 DBX20.4, 862
DBX102.7, 860 DBX20.5, 862
DBX107.0, DBX20.6, 863
DBX107.1, 887 DBX20.7, 863
DBX107.6, 856 DBX21.6, 864
DBX108.7, 300 DBX23.0, 159
DBX110.0 - 113.7, 547 DBX24.3, 867
DBX110.0-113.7, 889 DBX3.0, 891
DBX114.0 - 117.7, 547 DBX3.1, 891
DBX114.0-117.7, 889 DBX3.2, 892
DBX97.0-3, 156 DBX3.3, 892
DBX98.0-3, 156 DBX3.4, 892
DBX99.0-3, 156 DBX3.5, 893
DB10, ... DBX30.0, 874
DBX107.0, 445 DBX30.0-2, 179
DBX107.1, 445 DBX30.1, 874
DB11 DBX30.2, 874
DB6.2, 144 DBX30.3, 875
DBX 6.3, 299 DBX30.4, 875
DBX186.2, 144 DBX31.5, 875
DBX26.2, 144 DBX323.0, 159
DB11, ... DBX323.0, 327.0, 331.0,
DBX(n*20+6).2, 193 DBX327.0, 159
DB19 DBX33.3, 867
DBX0.7, 194 DBX33.6, 886
DBX20.7, 194 DBX331.0, 159
DB21, ... DBX332.4, 871
DBX0.3, 861 DBX332.5, 871
DBX0.6, 177 DBX332.6, 872
DBX100.5, 874 DBX332.7, 872
DBX101.5, 874 DBX335.0, 159
DBX102.5, 874 DBX335.0, 339.0, 343.0,
DBX12.0-2, 865 DBX336.4, 871
DBX12.0-5, 864 DBX336.5, 871
DBX12.3, 561 DBX336.6, 872
DBX12.4, 862 DBX336.7, 872
DBX12.5, 862 DBX339.0, 159
DBX12.6, 863 DBX340.4, 871
DBX12.7, 863 DBX340.5, 871
DBX13.6, 864 DBX340.6, 872
DBX15.0, 159 DBX340.7, 872
Extended Functions
Index
DBX343.0, 159 DBX40.4, 157

DBX37.0, 876 DBX40.6, 158
DBX37.0-2, 867 DBX41.6, 148
DBX37.1, 876 DBX46.4, 157
DBX37.2, 876 DBX46.6, 158
DBX377.4, 196 DBX52.4, 157
DBX377.5, 196 DBX52.6, 158
DBX38.0, 893 DB31, ...
DBX38.1, 893 DBB0, 894
DBX39.5, 876 DBB19, 742
DBX40.5, 157 DBB68, 886
DBX40.6, 869 DBB78-81, 897
DBX40.7, 869 DBB8, 885
DBX41.0-6, 870 DBX1.3, 734
DBX43.0, 159 DBX1.4, 735
DBX43.0, 49.0, 55.0, 870 DBX1.5, 736
DBX46.5, 157 DBX1.6, 736
DBX46.6, 869 DBX1.7, 145
DBX46.7, 869 DBX100.2, 900
DBX47.0-6, 870 DBX100.3, 900
DBX49.0, 159 DBX100.4, 900
DBX52.5, 157 DBX100.5, 901
DBX52.6, 869 DBX100.6, 901
DBX52.7, 869 DBX100.7, 901
DBX53.0-6, 870 DBX102.0, 234
DBX55.0, 159 DBX104.0 - 7, 901
DBX67.0, 884 DBX12.4, 902
DBX7.1, 737 DBX13.0-2, 880
DBX7.4, 737 DBX14.0, 316
DB21, DBX16.4, 741
DBX 36.5, 299 DBX16.5, 741
DBX12.0-2, 173 DBX16.7, 741
DBX13.6, 148 DBX17.6, 742
DBX16.0-2, 173 DBX2.0, 890
DBX20.0-2, 173 DBX2.1, 734
DBX320.0-2, 155 DBX2.2, 894
DBX324.0-2, 155 DBX25.0, 234
DBX328.0-2, 155 DBX26.4, 740
DBX332.4, 157 DBX28.0, 898
DBX332.5, 157 DBX28.1, 895
DBX332.6, 158 DBX28.2, 895
DBX332.7, 158 DBX28.3, 899
DBX336.4, 157 DBX28.4, 899
DBX336.5, 157 DBX28.5, 899
DBX336.6, 158 DBX28.6, 899
DBX336.7, 158 DBX28.7, 900
DBX340.4, 157 DBX29.5, 732
DBX340.5, 157 DBX31.4, 735
DBX340.6, 158 DBX31.5, 903
DBX340.7, 158 DBX4.0-2, 876
DBX35.7, 193 DBX4.3, 736
DBX377.5, 193 DBX4.4, 877
Extended Functions
Index
DBX4.5, 877 DB31,

DBX4.6, 878 DBX 61.2, 299
DBX4.7, 878 DBX4.0-2, 173
DBX5.0 - 5.5, 151 DBX64.4, 157
DBX5.0-5, 879 DBX64.6, 158
DBX5.6, 879 Defining geometry axes, 414
DBX6.2, 611 Deformation
DBX60.1, 857 due to temperature effects, 224
DBX60.4, 773 Delay time, 523
DBX60.4/5, 226 Delayed stroke, 892
DBX60.5, 773 Delete distance-to-go, axis-specific, 894
DBX60.6, 611 Determinism, 755
DBX60.7, 611 Differential speed, 740
DBX60.7 or DBX60.6, 212 Direction of rotation, 373
DBX61.1, 896 Disable analog NCK inputs, 840
DBX61.2, 857 Disable analog NCK outputs, 842
DBX61.3, 732 Disable digital NCK inputs, 837
DBX62.0, 890 Disable digital NCK outputs, 838
DBX62.1, 881 Disable synchronization, 903
DBX62.3, 887 Dressing during machining process, 816
DBX62.7, 857 DRF, 790
DBX63.0, 896 Dynamic backlash, 234
DBX63.1, 896 Dynamic NC memory, 755
DBX63.2, 896 Dynamic programming in spindle/axis operations, 746
DBX64.0-2, 881 Dynamic response
DBX64.4, 882 -adaptation, 283
DBX64.5, 882 Dynamic user memory, 763
DBX64.6, 882
DBX64.7, 882
DBX65.0 - 65.5, 151 E
DBX65.0-6, 883
Effects on HMI operation, 391
DBX67.0, 159
end-of-motion criterion
DBX7.0, 879
with block search, 628
DBX74.4, 902
Error
DBX75.0-2, 884
Angularity, 243
DBX75.3-5, 884
Leadscrew, 238
DBX76.5, 897
Measuring system, 238
DBX76.6, 906
Sag, 243
DBX83.1, 711
-temperature compensation curves, 224
DBX83.3, 908
Error during oscillation movement, 900
DBX83.5, 741
Example, 392
DBX83.6, 908
TRAANG, 426
DBX83.7, 741
TRACYL, 420
DBX84.1, 908
TRANSMIT, 419
DBX84.4, 903
Example of probe function test, 524
DBX98.0, 904
Exceptions, 385
DBX98.1, 904
Extensions, 384
DBX98.2, 904
External oscillation reversal, 898
DBX98.4, 905
DBX99.0, 905
DBX99.1, 906
DBX99.4, 733
Extended Functions
Index
F Path definition, 171

Programming and activation, 175
FC18, 629
Velocity override, 172
Feed override, 629
Handwheel selected (for handwheel 1, 2 or 3), 860
Feedforward control
Hardware limit switches, 213
Speed, 280
Hirth tooth system, 783
Torque, 282
Home NCU, 95
Feedforward control, 278
Feedrate override, 145
Feedrate override / spindle override axis-specific, 894
I
Feedrate/rapid traverse override, 210
FIFO variables, 448 I/O range, 54
FINEA, 618 INCH or METRIC unit of measurement, 464
Fixed point positions, 186 Inclined axis transformations, 417
Following error, 278 Incremental traversing, 151
Following spindle Indexing axes
Resynchronization, 733 Coded position, 777
Following spindle interpolator, 707 Commissioning, 786
Frames, 392 FRAMES, 781
FS (following spindle) active, 906 Handwheel, 773
Programming, 777
Reference point approach, 790
G Indexing axis
System of units, 776
G75, 183
Indexing axis in position, 906
General channel configuration, 427
Indexing positions
Geometry axis grouping are either, 337
Number, 776
Geometry monitoring, 908
Indexing positions table, 775
Geometry-axis manual travel, 209
Infeed, 641
GET, 326
INIT, 308
GETD, 327
Input values, 452
Grid structure, 253
Measurement types, 453
Grinding tools, 801
Setpoints, 455
GWPS, 829
Interface signals
in all operating modes, 831
Activate DRF, 861
GWPS active, 908
Activate handwheel (1 to 3), 876
Activate handwheel (1 to 3) for geometry axis (1, 2,
3), 865
H
Activate handwheel 1 as contour handwheel, 874
Handwheel Activate handwheel 2 as contour handwheel, 874
Assignment, 155 Activate handwheel 3 as contour handwheel, 874
Connection, 154 Active machine function INC1, ..., continuous, 883
Distance specification, 161 Active machine function for geometry axis (1, 2,
Path definition, 178 3), 870
Selection of HMI, 156 Continuous machine function, 879
Traversal in JOG, 154 Contour handwheel active (1 to 3), 867
Velocity specification, 178 Contour handwheel simulation on, 875
Handwheel connection Contour-handwheel-simulation negative
Ethernet, 206 direction, 875
Handwheel connection (828D) Define handwheel 1 as contour handwheel, 874
PPU, 201 Define handwheel 2 as contour handwheel, 874
PROFIBUS, 202 Define handwheel 3 as contour handwheel, 874
Handwheel override in AUTOMATIC mode DRF selected, 867
Extended Functions
Index
Handwheel 1 active as contour handwheel, 876 Interpolation point, 236

Handwheel 2 active as contour handwheel, 876 Interpolator
Handwheel 3 active as contour handwheel, 876 path, 606
Handwheel active (1 to 3), 881 Shaft, 606
Handwheel active (1 to 3) for geometry axis, 871 IPOBRKA, 618
Handwheel direction of rotation inversion active IPOENDA, 618
(geometry axis 1, 2, 3), 870 IS feedrate stop / spindle stop, 718
Handwheel direction of rotation inversion active for
contour handwheel, 876
Handwheel direction of rotation inversion for J
geometry axis (1, 2, 3), 865
JOG, 392
Handwheel direction of rotation inversion for
Approaching a fixed point, 183
orientation axis (1, 2, 3),
jog mode, 152
Handwheel override active, 881
JOG retract, 190
Invert handwheel direction of rotation (machine
axes), 879
Invert handwheel direction of rotation active
L
(machine axes), 884
Invert handwheel direction of rotation for contour Language command
handwheel, 875 SPN, 576
JOG - Approaching fixed point 0/1/2, 880 SPP, 575
JOG - Approaching fixed point active, 884 Language commands, 562
JOG - Approaching fixed point reached, 884 LEC, 238
Machine function continuous for geometry axis (1, Linked transformation
2, 3), 864 Example, 389
Machine function for geometry axis (1, 2, 3), 870 Logical start address, 54
Machine function INC1, INC10, INC100, INC1000, Longitudinal grooves, 348
INC10000, INCvar, 879 LS (leading spindle) active, 905
Plus and minus traverse keys, 878
Plus and minus traversing command, 882
Plus and minus traversing command (for orientation M
axis), 872
Machine axis (for handwheel 1, 2 or 3), 860
Plus and minus traversing commands (for geometry
Machine axis identifier, 268
axis), 869
Manual stroke initiation, 893
Plus and minus traversing keys for geometry axis
Manual travel, 209
(1, 2, 3), 863
MCP switchover disable, 853
Plus and minus traversing request, 882
MD10010, 307
Plus and minus traversing request (for geometry
MD10050, 83
axis), 871
MD10061, 84
Plus and minus traversing request (for orientation
MD10070, 84
axis), 871
MD10071:, 84
Rapid traverse override, 877
MD10088, 300
Rapid traverse override for geometry axis (1, 2,
MD10185, 84
3), 862
MD10200, 296
Traversing key disable for geometry axis (1, 2,
MD10210, 697
3), 862
MD10260, 544
Traversing key lock, 877
MD10270, 776
Interpolation
MD10300, 28
Linear, 606
MD10310, 28
non-linear, 607
MD10320, 38
with G0, 606
MD10330, 42
Interpolation functions, 636
MD10350, 35
Extended Functions
Index
MD10360, 35 MD11410, 300

MD10361, 36 MD11450, 571
MD10362, 29 MD12701, 133
MD10364, 29 MD12702, 133
MD10366, 29 MD12703, 133
MD10368, 29 MD12704, 133
MD10394, 49 MD12705, 133
MD10395, 49 MD12706, 133
MD10396, 49 MD12707, 133
MD10397, 49 MD12708, 133
MD10398, 49 MD12709, 133
MD10399, 50 MD12710, 133
MD10450, 545 MD12711, 133
MD10460, 552 MD12712, 133
MD10461, 552 MD12713, 133
MD10470, 548 MD12714, 133
MD10471, 548 MD12715, 133
MD10472, 548 MD12716, 133
MD10473, 548 MD12717, 106
MD1048, 550 MD12750, 102
MD10480, 551 MD13211, 449
MD10485, 551 MD17900, 163
MD10500, 56 MD18000, 85
MD10501, 56 MD18050,
MD10502, 57 MD18060, 761
MD10510, 56 MD18096, 807
MD10511, 56 MD18100, 806
MD10512, 61 MD18210, 763
MD10530, 45 MD18230, 759
MD10531, 45 MD18351, 501
MD10540, 46 MD18352, 761
MD10541, 46 MD18353, 761
MD10720, 191 MD18600, 456
MD10721, 192 MD18720, 76
MD10722, 631 MD18960, 616
MD10735, 195 MD20050, 683
MD10900, 786 MD20070, 711
MD10910, 786 MD20100, 465
MD10920, 786 MD20110, 831
MD10930, 786 MD20112, 321
MD10940, 781 MD20120, 831
MD11300, 153 MD20130, 831
MD11310, 164 MD20150, 559
MD11320, 161 MD20151, 196
MD11322, 178 MD20254, 824
MD11324, 162 MD20350, 826
MD11330, 173 MD20360, 465
MD11346, 186 MD20390, 228
MD11350, 203 MD20610, 824
MD11351, 203 MD20620, 162
MD11352, 203 MD20621, 162
MD11353, 203 MD20624, 169
Extended Functions
Index
MD20700, 197 MD32200, 744

MD20730, 608 MD32300, 616
MD20750, 607 MD32301, 146
MD21106, 405 MD32400, 746
MD21150, 698 MD32410, 746
MD21158, 211 MD32420, 746
MD21159, 211 MD32430, 746
MD21166, 210 MD32431, 616
MD21168, 210 MD32436, 146
MD21220, 47 MD32450, 233
MD21300, 743 MD32452, 233
MD21310, 744 MD32456, 235
MD21320, 744 MD32457, 235
MD21330, 744 MD32490, 295
MD21340, 744 MD32500, 295
MD22550, 796 MD32510, 295
MD22560, 797 MD32520, 296
MD24120, 406 MD32530, 296
MD26000, 567 MD32540, 290
MD26002, 567 MD32550, 295
MD26004, 567 MD32560, 295
MD26006, 567 MD32570, 295
MD26010, 579 MD32610, 744
MD26014, 583 MD32620, 744
MD26016, 579 MD32630, 279
MD26018, 568 MD32650, 744
MD26020, 568 MD32700, 239
MD28264, 448 MD32710,
MD30300, 777 MD32711, 250
MD30310, 777 MD32720, 250
MD30320, 787 MD32730, 250
MD30330, MD32750, 288
MD30340, 689 MD32760, 228
MD30455, MD32800, 744
MD30460, MD32810, 744
MD30500, 786 MD32900, 284
MD30503, 688 MD32910, 745
MD30505, 784 MD34080, 748
MD30550, 711 MD34090, 748
MD30552, 605 MD34100, 748
MD30600, 186 MD35000, 711
MD31090, 178 MD35032, 831
MD32000, 607 MD35040, 831
MD32010, 145 MD35220, 747
MD32020, 212 MD35230, 747
MD32040, 773 MD35242, 747
MD32050, 773 MD36100, 692
MD32060, 631 MD36110, 692
MD32074, 337 MD36500, 233
MD32080, 162 MD36610, 299
MD32084, 164 MD36620, 299
MD32090, 181 MD37200, 745
Extended Functions
Index
MD37210, 745 Memory expansion, 760

MD37220, 745 Memory organization, 755
MD37230, 748 Minimum interval between two consecutive
MD37500, 614 strokes, 568
MD37510, 614 Minus
MD37511, 614 -output cam, 535
MD38000, 239 Minus cam signals 1-32, 889
MD7200, 748 Mode group, 306
MEASA, MEAWA, MEAC commands, 446 Modes, 214
Measurement Modified activation of machine data, 786
of angle in a plane ($AC_MEAS_TYPE = 17), 485 Modulo 360, 685
of groove ($AC_MEAS_TYPE = 12), 477 Modulo rotary axis
of hole ($AC_MEAS_TYPE = 8), 473 as indexing axis, 777
Of oblique edge ($AC_MEAS_TYPE = 16), 483 Working-area limitation, 692
of shaft ($AC_MEAS_TYPE = 9), 476 Monitoring functions, 213
of web ($AC_MEAS_TYPE = 13), 480 Monitoring of the input signal, 568
Measurement input parameters, 458 Monitoring status with modulo rotary axes, 902
Measurement interface Monodirectional probe, 443
Diagnostics, 465 Motion behavior, 636
Input values, 453 MSEC, 238
Output values, 460 Multidirectional probe (3D), 443
Measurement method Multiplication
for coordinate transformation of a position Table, 245
($AC_MEAS_TYPE = 24), 496
For defining an additive rotation of the active or
selected plane ($AC_MEAS_TYPE = 28), 503 N
For determining a triangle ($AC_MEAS_TYPE =
NCK treats the axis as a positioning axis, 897
25), 500
NCU link, 267
For restoring the value assignments of data
NCU link active, 856
management frames ($AC_MEAS_TYPE = 27), 502
NCU link axis active, 857
For saving data management frames with current
Neutral axis, 320
value assignments to a file ($AC_MEAS_TYPE =
No stroke enable, 891
26), 501
Not transformation-specific, 418
Measurement of tool diameter ($AC_MEAS_TYPE =
Number
11), 507
Transformations, 379
Measurement results
Number of chained transformations, 388
MEAC, 450
Number of transformations, 388
MEAS, MEAW, 445
MEASA, MEAWA, 449
Measuring
O
Compensation of the delay time, 523
Delay time of the measuring signal, 523 Operating mode
Maximum traversal speed, 523 JOG, 144
Measurement accuracy, 523 Operating mode changeover rejected, 854
Traversal speed during the measurement, 523 Optimization of velocity control, 382
Measuring cycles, 462 Orientation transformations, 416
Measuring mode, 447 OS, 646
Measuring probe OSB, 649
-types, 442 OSCILL, 655
Measuring process, 523 Oscillating, 641
Measuring status, 887 asynchronous, 641
Mechanical backlash, 231 continuous infeed, 641
Extended Functions
Index
with synchronized actions, 667 Positioning axes, 600

Oscillating axis, 641 Axis types, 603
Oscillation active, 901 Axis-specific signals, 630
Oscillation cannot start, 900 Channel-specific signals, 630
Oscillation movement active, 901 Concurrent, 629
Oscillation reversal active, 900 Dry run feedrate, 635
OSCTRL, Maximum number, 617
OSE, 649 Tool offset, 620
OSNSC, 649 Types, 603
OSP, 647 Positioning axis dynamic response, 616
OST, 647 Position-time cams, 551
Output cam POSP, 655
-pair, 535 Power On, 398
-positions, 543 Preset actual value memory, 451
-range, 535 for geo axes and special axes ($AC MEAS TYPE =
-signals, 535 14), 481
Output values, 452 for special axes ($AC MEAS TYPE = 15), 482
Overlap areas of axis angles Probe actuated, 887
TU address, 402 Probe function test, 524
Overwrite screen form for analog NCK outputs, 841 Processing
Overwrite screen form for digital NCK outputs, 838 face-end, 347
PROFIBUS I/O, 54
Program
P -coordination, 308
Programming of joint position
p0680, 449
STAT address, 401
p0684, 449
Programming with groove wall offset, 422
p0922, 449
Programming without groove wall offset, 424
Part program, 430
PTP/CP switchover
Passive file system, 756
Mode change in JOG, 404
path
PUNCHACC, 569
-interpolator, 606
Path default using handwheel, 178
Path segmentation, 573
R
Permanently configured coupling, 707
Plane separation, 455 RangeIndex, 60
PLC axes, 629 RangeOffset, 60
PLC axis, 330 Rapid traverse
axes under exclusive PLC control, 630 Interpolation types, 606
permanently assigned PLC axis, 630 Rapid traverse override, 145
start via FC18, 632 Read offset, 718
PLC controls axis, 900 Reconfiguration, 757
PLC service display, 450 Redefine WCS on the oblique plane
PLC-controlled axis, 896 ($AC_MEAS_TYPE = 18), 488
Control response to MD30460 bits 6 and 7, 634 Reference point approach, 182
Plus RELEASE, 325
-output cam, 535 Release guide axis, 325
Plus cam signals 1-32, 889 Replaceable geometry axes, 374
Position of tool zero, 374 Replaceable geometry axis, 354
Position offset Reset, 399
In synchronous spindles, 732 Response to setpoint changes, 744
Position switching signals, 535 Resynchronization, 732
Lead/delay times, 545 Reversal points, 641
Extended Functions
Index
Rotary axes, 681 SD42100, 644

Absolute programming, 694 SD42101, 644
Axis addresses, 682 SD42300, 744
Commissioning, 697 SD42400, 565
Feedrate, 684 SD42402, 568
Incremental programming, 696 SD42404, 568
Mirroring, 699 SD42600, 774
Modulo 360, 685 SD42650, 406
Modulo conversion, 694 SD43300, 774
Operating range, 683 SD43400, 692
Positioning display, 684 SD43410, 692
Software limit switch, 698 SD43600, 628
Units of measurement, 683 SD43770, 649
Rotary axis, 681 SD43790,
Rotational position, 373 SD43900, 227
RTLIOF, 608 SD43910, 227
RTLION, 608 SD43920, 230
Running-in Selection, 399
Channel-by-channel, 315 Selection and deselection, 390
Selection of tool or cutting edge, 458
Separate following spindle interpolator, 707
S Series machine start-up file, 757
Set reversal point, 899
Sag compensation, 267
Set value by PLC of the digital NCK outputs, 839
Scratching, 451
SETM, 313
SD41010, 173
Setpoint for analog NCK outputs, 845
SD41040, 772
Setpoint for digital NCK outputs, 845
SD41050, 772
Setpoints, 455
SD41100, 773
Setting by PLC of the digital NCK inputs, 838
SD41110, 212
Setting screen form for analog NCK inputs, 840
SD41120, 214
Setting screen form for analog NCK outputs, 841
SD41130, 698
Setting screen form for digital NCK outputs, 839
SD41200, 212
Setting value from PLC for analog NCK inputs, 840
SD41300, 245
Setting value from PLC for analog NCK outputs, 842
SD41500, 543
Single axes
SD41500 - 41507, 776
Applications, 610
SD41501, 543
Axis control by PLC, 609
SD41502, 543
Extended retract numerically controlled, 614
SD41503, 543
Extended stop numerically controlled, 613
SD41504, 543
Single block
SD41505, 544
SD41506, 544
SD41507, 544
SD41520, 552
Single transformations, 428
SD41521, 552
Slot side compensation, 348
SD41522, 546
Software
SD41523, 546
-output cam, 535
SD41524, 546
Software limit switch, 790
SD41525, 546
Sparking-out active, 901
SD41526, 552
Sparking-out strokes, 641
SD41527, 552
Special features, 400
SD41600, 46
Special features of JOG, 377
SD41601, 46
Extended Functions
Index
Speed monitoring, 908 Tool offset for grinding tools, 801

Spindle manual travel, 211 Tool types for grinding tools, 805
Spindle number, 807 TRAANG
Spindle replacement, 320 Brief description, 349
START, 308 Restrictions, 384
Static NC memory, 755 TRACYL, 348
Static user memory, 759 Axis image, 371
Stop along braking ramp, 899 Number, 369
Stop at next reversal point, 899 Tracyl transformations, 417
Stroke initiation active, 893 TRACYL_BAE_TOOL_t, 374
Stroke inoperative, 892 TRACYL_ROT_AX_OFFSET_t, 373
Stroke suppression, 892 TRACYL_Rot_Sign_IS_PLUS_t, 373
Superimposed motion, 905 TRANS, 696
Supplementary conditions, 399 Transformation
switching accuracy Chaining sequence, 388
of the cam signals, 548 Transformation active, 886
Synchronism coarse, 904 Transformation chain, setpoint positions, 395
Synchronism fine, 904 Transitions of possible axis states during axis
Synchronized state reached, 716 replacement, 324
Synchronous mode, 903 Translation, 406
Deactivate, 725 Translational offsets, 455
Knee-shaped acceleration characteristic, 747 TRANSMIT, 347
Synchronous spindle Transmit transformations, 416
Position offset, 732 TRANSMIT_ROT_AX_OFFSET_t, 352
System variable, 449 Transverse axes, 215
Transverse grooves, 348
Traversing keys, 148
T Traversing range limitation for modulo rotary axes, 902
Trigger event, 447
table
Compensation,
Telegram selection, 449
U
Temperature
-compensation, 224 User-defined coupling, 707
-influence, 224
Coefficient tan(T), 230 V
Time constant
Variable interface, 452
Dynamic response adaptation, 283
Velocity, 212
Tool change
Velocity and acceleration, 214
Fixed points, 797
Velocity control, 385
Sequence, 795
Tool change point, 797
Tool change times, 796
W
Tool length
($AC_MEAS_TYPE = 10), 505 WAITE, 309
Measurement with stored or current position WAITM, 308
($AC_MEAS_TYPE = 23), 509 WAITMC, 311
measurement with zoom-in function WAITP, 619
($AC_MEAS_TYPE = 22), 508 Oscillating axis, 654
Tool measuring, 504 Working-area limitation, 213
Two turning tools each with their own reference Workpiece measuring, 452
point, 511 Write online tool offset discretely, 823
Extended Functions
Index
X
x edge ($AC_MEAS_TYPE = 1), 466
Y
y edge ($AC_MEAS_TYPE = 2), 468
Z
z edge ($AC_MEAS_TYPE = 3), 469
Extended Functions
Index
Extended Functions

Sinumerik 840D SL - 828D - Extended Functions

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 Extended Functions ___________________

Siemens AG Order number: 6FC5397-1BP40-3BA1 Copyright Siemens AG 1994 - 2013.

My Documentation Manager (MDM)

Information on structure and contents

Notation of system data

Signal/Data Notation Example

Type Meaning Range of values

2 B3: Distributed systems - 840D sl only .................................................................................................... 71

2.3 Examples ...................................................................................................................................122

3.5 Handwheel override in automatic mode.................................................................................... 170

3.12.3.6 Signals to axis/spindle ...............................................................................................................221

4.6.4 Friction compensation with acceleration-dependent compensation value ............................... 294

5.6 Data lists ....................................................................................................................................343

6.6.3 Examples of ambiguities of position.......................................................................................... 403

7.5.3 Types of workpiece measurement.............................................................................................466

8.2.3 Cam positions ........................................................................................................................... 543

9.9 Data lists ....................................................................................................................................596

10.10.3 Signals....................................................................................................................................... 638

12.3 Programming rotary axes...........................................................................................................688

13.7 Data lists.................................................................................................................................... 750

15.8 Examples ...................................................................................................................................791

17.4.3 Speed monitoring ...................................................................................................................... 827

18.9 Punching and Nibbling (N4) .......................................................................................................891

Table 1- 1 Maximum number of digital and analog NCK I/Os

Total NCU on-board External NCK I/Os

Access to NCK I/Os:

1.2 Access via PLC

1.2.1 Brief description

Configuring NCK I/Os

PLC I/Os for direct addressing by NCK

1.2.2 Configuration of the NCK I/Os

Number of active NCK I/Os

MD10350 $MN_FASTIO_DIG_NUM_INPUTS Number of active digital NCK

Hardware assignment of the external NCK I/Os

MD10366 $MN_HW_ASSIGN_DIG_FASTIN[<n>] HW assignment for external

Weighting factor for the analog NCK I/Os

MD10320 $MN_FASTIO_ANA_INPUT_WEIGHT[<n>] Weighting factor for the analog

Byte address Assignment for the digital NCK I/Os

1.2.3 NCK digital inputs/outputs

1.2.3.1 NCK digital inputs

Read actual value

Set input from PLC

Behavior during POWER ON / reset

1.2.3.2 NCK digital outputs

Behavior at program end / reset

Digital NCK outputs without hardware

1.2.3.3 Connection and logic operations of fast digital NCK I/Os

1.2.4 NCK analog I/Os

1.2.4.1 NCK analog inputs

Read actual value

Set input from PLC

Binary analog-value display

Behavior during POWER ON / reset

Analog NCK input without hardware

1.2.4.2 NCK analog outputs

Binary analog-value display

Behavior at program end / reset

Analog NCK outputs without hardware

1.2.4.3 Representation of the NCK analog input/output values

Minimum value Maximum value

Resolutions < 16 bits

Representation of the maximum value for different resolutions

Example 1: Analog value = 9.5 V

Extended Functions ___________________

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